Broken tap - Ford Powerstroke Diesel Forum
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post #1 of 12 Old 08-26-2007, 05:51 PM Thread Starter
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Angry Broken tap

I was installing the thermocouple for my pyro this evening and half of the tap is stuck in the exhaust manifold. I was using cutting oil and clearing the threads after every 1/2 turn. It is a Snap-on tap, 1/8-27 NPT. The tip of the tap is pretty much flush with the manifold and I can't get a bit to drill through the hardened steel. Any ideas on what I can do?

Thanks.


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-Wayne
1999.5 F-250 4x4 CC SB 8" DR Lift / 37x12.50r17 ProComp Xtreme A/T's / 4.56 Gears / Pyro, Boost, Tranny guages / DP-Tuner (Stock, NoStart, 60T, 80E, 120R) / Wicked Wheel / 4" Turbo Back MBRP Aluminized / AFE Stage 1 PG7 / ITP Overboost Annihilator / 203* Thermostat / CCV Mod / AIH Delete / Foil Delete / TireGate VT Series
(Awaiting install: Powerslot Cryo rotors & Hawk LTS pads)
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post #2 of 12 Old 08-26-2007, 05:54 PM
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Could always start over and drill a new one. You can't get any kind of a hole drilled to ez out the tap?

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Turbo Back 4" Silverline Exhaust Mbrp Muffler Delete
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post #3 of 12 Old 08-26-2007, 05:59 PM
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Smash it with a hammer. show that tap whose in charge
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post #4 of 12 Old 08-26-2007, 06:04 PM
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If you know any welders, try get them to weld a nut onto it and spin it back out. The nut may break off a couple of times, because the tap is made of extremely hard material, but it will eventually come out. Quit trying to drill it out, you'll never be able to drill it.
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post #5 of 12 Old 08-26-2007, 06:16 PM
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You can try and grind a slot in it with a dremel with some type of fine grinding tool then stick a flathead in there to see if it would come out that way first, then go onto other means of getting it out.
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post #6 of 12 Old 08-26-2007, 06:20 PM
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Take a chisel or punches that you can hit the tap with it might break up enough to get out.

2002 F-250 4x4 EC, SRW, SB
Auto 93,000 miles
DP Tuner F5
ATS Compressor and 1.0 Exhaust housing high flow back plate
Turbo Back 4" Silverline Exhaust Mbrp Muffler Delete
Isspro Trans,Pyro,Boost Triple Pod
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AIH Delete With Boost Fitting


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post #7 of 12 Old 08-26-2007, 06:20 PM
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you may want to pull the manifold, there not as bad as you think to get off ,
get it on a bench where you can work with it , if you still cant seem to get it out , have someone weld the hole up , and drill and tap near it again


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ITS STOCK
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post #8 of 12 Old 08-26-2007, 06:24 PM
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I have broke more than one ....

The dont break flush ...... take a small screwdriver and catch the edge and tap it with a hammer spinning it counter clockwise ...... the come out easy enough
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post #9 of 12 Old 08-26-2007, 07:12 PM Thread Starter
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I found this: Tap Extractor

Should be on its way tomorrow. Thanks for all the replies.


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-Wayne
1999.5 F-250 4x4 CC SB 8" DR Lift / 37x12.50r17 ProComp Xtreme A/T's / 4.56 Gears / Pyro, Boost, Tranny guages / DP-Tuner (Stock, NoStart, 60T, 80E, 120R) / Wicked Wheel / 4" Turbo Back MBRP Aluminized / AFE Stage 1 PG7 / ITP Overboost Annihilator / 203* Thermostat / CCV Mod / AIH Delete / Foil Delete / TireGate VT Series
(Awaiting install: Powerslot Cryo rotors & Hawk LTS pads)

Last edited by pwrdby4d; 09-04-2007 at 09:24 AM.
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post #10 of 12 Old 09-04-2007, 09:17 AM
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If it is a Snap On tap the Snap On truck should have a tool to remove the broken tap so that you don't have to remove the manifold.
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