Bolt head broke off of turbo bolt, Need help!

[dhkemp91]

This started off as me just going in to swap my transmission. I got everything out of the way and got the old transmission out with no problems. There was an exhaust leak at the turbo tho, so while i was down there i was going to take the pipe off and put a new gasket on. When i tried to unbolt it one of the heads of the bolts broke off. I have tried almost everything i can think of and cant get the bolt out. So i guess my question is what would be the best/easiest solution? taking the turbo off? is that possible ? need some suggestions! Thank you!

[z32loverboy]

Post pics so we can see exactly what you're talking about. From what i'm guessing (i'm not a TT guy just yet) if it's possible to take the turbo off you might be able to get a pair of pliers on the bolt itself and torque it out that way. Pics would defiantly help.

[NolimitZ32]

Which bolt is it?

[ThisIsSparTTa]

Vice grips?

[dhkemp91]

It is the upper right most bolt on the driver side turbo. I have tried everhthing. Tried filing down both sides of it and using a cresent. Tried heating it up, using vice grips, and the spray stuff. It won't budge.

[ThisIsSparTTa]

Is the rest of the turbo off? I seem to remember at one job I worked there was a drill attachment for removing bolts stuck like that. I just did a quick google search for removing a bolt without a head with a drill, and I believe the device you'll want is called a "reamer" it basically drills into the bolt some, and then digs into it, allowing you to unscrew it. I'd probably only attempt that with the turbo off, if possible to avoid damaging the mount hole on the turbo.

[dhkemp91]

Unfortunately the turbo is still on the car. How difficult is it to remove the turbo from underneith? What all has to be removed?

[NolimitZ32]

Unfortunately the turbo is still on the car. How difficult is it to remove the turbo from underneith? What all has to be removed?

Not impossible, but so difficult that pulling the engine or a head is MUCH less work. All I can suggest is try getting a socket type extractor kit that will fit over the bolt. PB Blaster and elbow grease is pretty much my only suggestion.

[Ziggy1621]

Are you talking about the downpipe bolt? The turbo is held on by nuts.

[dhkemp91]

Yeah it's the bolt that held that downpipe on. Going through the downpipe into the turbo.

[Ziggy1621]

So, to get the picture, your down pipe is off, but there is a stud still in the exhaust housing correct?

[dhkemp91]

Correct! I would have actual pictures but I haven't had time to get out there.

[Ziggy1621]

Well you may have hosed my idea with the file, but you can get two nuts spun onto the shaft. Then you turn them into themselves and they will lock together in the threads. Then you turn the inner nut counter clockwise. It locks against the outer nut and should turn the shaft.

If you can get one nut on, maybe weld it on. Put it on backwards so you weld the bottom of the nut pointing out. Then put a flare nut wrench on the nut and try to turn it.

[dhkemp91]

I had never thought of that. Hopefully I can get the nuts on somehow. I have a tap and die set so I could re-die the stud and possible get that to work. Thanks!

[t.mcginley.jr]

Well you may have hosed my idea with the file, but you can get two nuts spun onto the shaft. Then you turn them into themselves and they will lock together in the threads. Then you turn the inner nut counter clockwise. It locks against the outer nut and should turn the shaft.

If you can get one nut on, maybe weld it on. Put it on backwards so you weld the bottom of the nut pointing out. Then put a flare nut wrench on the nut and try to turn it.

This trick comes in handy alot. I used it to get the old idler studs out to replace them with Ramey Z ones, the nuts just have to be locked tight enough together. Welding them is a good idea, I never thought of that.

[dhkemp91]

Unfortunately I don't think there is enough exposed to get two nuts on there. Think I'm going to have to resort to the welding option. Gotta love finding a reason to buy a new tool!

[Ace2cool]

Unfortunately I don't think there is enough exposed to get two nuts on there. Think I'm going to have to resort to the welding option. Gotta love finding a reason to buy a new tool!

New tool day is always a fun day.