Broken oil rail bolt - Ford Powerstroke Diesel Forum
6.0L Performance Parts Discussion What has or has not worked for you?

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post #1 of 8 Old 09-28-2013, 02:06 AM Thread Starter
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Broken oil rail bolt

While finishing up my d-plugs, and stand pipes, and stc fitting. I broke 1 oil rail bolt with the torx head on it and two valve cover bolts any one have this experience before and any idea how to remove?

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post #2 of 8 Old 09-28-2013, 04:09 AM
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That sucks, the torque on those is not supposed to be much. You got to drill inside the bolt and by the special bit that screws in reverse thread into the hole and walks your bolt out. Pain in the butt

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post #3 of 8 Old 09-28-2013, 07:59 AM
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Take your oil rail off and there should be enough of the bolt sticking out to grab with pliers or vise grips, same with the valve cover bolts. I would avoid drilling at all cost. If it broke off flush and you can't grab it try using a pick to spin it out. Without any pressure on them they should be loose enough to get out without having to use a easy out. Keeping the shavings out of the engine while drilling specially for the oil rail is damn near impossible.
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post #4 of 8 Old 09-28-2013, 11:45 AM
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Quote:
Originally Posted by Friz186 View Post
Take your oil rail off and there should be enough of the bolt sticking out to grab with pliers or vise grips, same with the valve cover bolts. I would avoid drilling at all cost. If it broke off flush and you can't grab it try using a pick to spin it out. Without any pressure on them they should be loose enough to get out without having to use a easy out. Keeping the shavings out of the engine while drilling specially for the oil rail is damn near impossible.
Lol, if you didn't try these steps BEFORE you posted your helpless lol. You always want to try to back it out on its own before you drill. If you have to drill, rags a vacum and grease(apply around area shavings will stick to it) will help

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post #5 of 8 Old 09-28-2013, 04:56 PM
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As far as drilling goes, mask off the surrounding area, even cover the bolt with duct tape, totally seal off everything around it. You can use grease as rob mentioned, others use magnets, and vacuum cleaner, but obviously magnet doesnt help with aluminum. If it wont spin out easily, as others have mentioned, or if here is not enough bolt sticking out to grab with vice grips, you can take a very acute punch, very sharp punch and try to spin it out, ive gotten them out that way before. Also, if it wont come out by hand spinning it, theres a 50/50 chance that an easy out wont work either. If it doesnt youll have to drill it out entirely and replace with a helicoil or key lock insert. Drilling a steel bolt out of aluminum is always difficult because if the drill bit isnt pefectly centered in the bolt, youll wind up drilling into the aluminum. Once the spinning drill bit hits the aluminum, itll drift further off center, because the aluminum is easier to cut than the steel bolt. If it doesnt come out easily pm me and i can give you lots of ways to get the bolt out or drill and replace with helicoil or thread insert. I take out a handful of broken bolts every day, 6.0s break the exhaust manifold bolts off or strip em out all the time. Its rare a day at work goes by that i dont take out broken bolts, theres lots of little tricks you can try to get the bolt out. Anyway good luck.



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post #6 of 8 Old 09-30-2013, 02:38 PM Thread Starter
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bolt came right out i used pliers thanks for all your help!

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post #7 of 8 Old 12-19-2014, 02:30 PM
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Where did you find a bolt to replace it. The dealer ships around me don't have them
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post #8 of 8 Old 12-21-2014, 01:47 PM
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Quote:
Originally Posted by Gearhead2012 View Post
As far as drilling goes, mask off the surrounding area, even cover the bolt with duct tape, totally seal off everything around it. You can use grease as rob mentioned, others use magnets, and vacuum cleaner, but obviously magnet doesnt help with aluminum. If it wont spin out easily, as others have mentioned, or if here is not enough bolt sticking out to grab with vice grips, you can take a very acute punch, very sharp punch and try to spin it out, ive gotten them out that way before. Also, if it wont come out by hand spinning it, theres a 50/50 chance that an easy out wont work either. If it doesnt youll have to drill it out entirely and replace with a helicoil or key lock insert. Drilling a steel bolt out of aluminum is always difficult because if the drill bit isnt pefectly centered in the bolt, youll wind up drilling into the aluminum. Once the spinning drill bit hits the aluminum, itll drift further off center, because the aluminum is easier to cut than the steel bolt. If it doesnt come out easily pm me and i can give you lots of ways to get the bolt out or drill and replace with helicoil or thread insert. I take out a handful of broken bolts every day, 6.0s break the exhaust manifold bolts off or strip em out all the time. Its rare a day at work goes by that i dont take out broken bolts, theres lots of little tricks you can try to get the bolt out. Anyway good luck.
I use my MIG to do all broken fasteners. Build it up and grab it with an extractor. I also have drill guides for 6.0/6.4s and 6.8/5.4/4.6s exhaust manifolds. I only go for those as an emergency.

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Quote:
Originally Posted by mayfikyl View Post
Where did you find a bolt to replace it. The dealer ships around me don't have them
I have the part number at work for the oil rail bolt, if you need it I'll get it.
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