broke rocker cover bolt

fredsub · Post by **fredsub** » Sun Sep 06, 2009 5:53 pm

EJ25 Passenger side and yeah its the one thats real difficult to get to...
so I removed nuts to front crossmember and engine pitching stopper, then jacked engine up maybe 5cm.

All in attempt to tighten those bolts to fix the nuisance oil drip at the lower
side of rocker cover. Previously i looked for what the torque settings should be but couldn't find it, found it NOW though! T2 3.6ft-lbs
Anyway can't get a torque wrench in there anyway.

In hindsight I shouldv'e realized the bolt was yielding, should have taken it out first and got a NEW one, it was looking worn before I got to it.....
hey maybe it was already broke or nearly so........

So now I need some advice on those easyout or screw extractor

like these I suppose

So just how easy do they work, I fear the engine will have to be removed to get a decent purchase in the bolt hole ?

and if the thread is stipped, helicoil ? the thread bit is ~5-6mm ............??

i've not removed a ej motor before.....ea82 was simple tho.
hmmm decisions...opportunity to buy some more tools....or give it to the mech at the workshop lol
This job prompted me prior to invest in a $260 3/8" socket set....
always used 1/2"in before, but bit frustrating with it at times working on the OBW.

BaronVonChickenPants · Post by **BaronVonChickenPants** » Sun Sep 06, 2009 6:26 pm

I've got a nice 1/2" drive set but always seem to get myself in trouble with it working with soft stuff like alloy, 3/8" set and a "bucket of careful" are next on my tool list.

"Easy Outs" don't always live up to their name, the most success i have had is if you can file/grind the remaining bolt flat, centre punch it, then gradually work up in drill sizes to the size you're easy out of choice requires, but don't go too small, if you think a broken bolt is bad, try a broken bolt with a broken easy out stuck in it.

If you can remove the rocker cover and expose a sizable section of bolt, I would start by trying to file 2 flat edges on opposing sides and grabbing it with a spanner (NOT a shifter), bolts that clamp an external item to the block/heads, like rocker covers, will usually come out very easily because with out the head there is no clamp force holding it in place....unless of course it's frozen in by rust/crud.

Good luck.

Jordan.

subybrumby · Post by **subybrumby** » Sun Sep 06, 2009 7:15 pm

My son is a fitter and he says,"if it won't come out easy with an easy out then it won't come out easy at all."' Baron von chickenpants has good advice. I had a broken bolt in the head of an EA82 that holds the aircon/alternator bracket onto the engine. Go with the advice in the previous post and the story is, "steady as you go".

fredsub · Post by **fredsub** » Sun Sep 06, 2009 9:17 pm

thanks for the advice.

did a bit of google research and this is of interest
Left Hand Drill Bits Set

This 5pc H.S.S left hand drill bit set makes it much easier to extract broken bolts and studs without having to pre drill first, as you would do when using a regular screw extractor. These bits have a 135 degree split point which makes it a self starting drill bit. To use these, you put the drill bit in your drill and start drilling the bolt or stud with the drill in reverse. In most cases, the bolt or stud will begin to back itself out. Sizes included: 1/8",3/16",1/4",5/16" and 3/8" drill bits. Comes in a pouch. This set extracts right hand bolts and studs up to 1".

http://www.toolprice.com/product/1217C/ ... l_Bit.html

didn't find any reference for them here in Australia.

ScubyRoo · Post by **ScubyRoo** » Mon Sep 07, 2009 3:44 pm

In the process of reinstalling my oil and water pumps i managed to break 3 bolts... the first was surprising, the second was frustrating, and after the third one i went and bought new bolts - not a broken one then, and i only did one with the torque wrench, rest by hand. Stupid torque wrench.

Luckily for me they all broke with enough bolt extruding from the block to pull out with a pair of vice-grips. The engine was out so easy enough job.

This is probably a dumb question, but have you taken the rocker covers off to check if you can grip the bolt or not? I like the file and spanner idea, would work well.

fredsub · Post by **fredsub** » Tue Sep 08, 2009 6:47 pm

haven't taken covers off yet! just collecting everything I might need....
ordered replacement gaskets,bolts etc.
got a screw extractor set, and 2 cobalt drill bits.
I could order left-hand drill bits from Blackwoods, $11.xx for 5mm, $7.?? for 3mm.....might be handy......

now the subaru parts guy said the gaskets are normally put in dry, aren't they????

so whats the story?

I haven't found the page/info on rocker covers in the pdfs of manual I've got.....

who can identify the red stuff in the pic...

researched three bond stuff, didn't find anything RED! so need help identifying what it *might* be?

Thanks

phillatdarwin · Post by **phillatdarwin** » Tue Sep 08, 2009 10:49 pm

the red stuff is just hi temp silicon not good to used on a engine the blue one is the go a bit pricee but just a small bit a lite smear is the way to do it