Ok, so this is a problem. I was removing my manifold today in an attempt to identify an exhaust leak. After getting it off, I'm unbolting the wastegate from the manifold when the head of one of the allen bolts literally snaps off. By the looks of it, the bolt is bent as well.

The remnants of the bolt are pretty securely wedged into the hole. I'm almost certain the hole will need to be redrilled and tapped, but that's getting ahead of myself at this point. I've tried vise-gripping it extremely tightly but no dice.

Any tips on what to do here? i figure racer-types are usually stuck in strange situations so hopefully someone can help me!

Pictures of failure:

 

Have you tried heating it, and then using some gloves with the vice grips?

 

Soak with wd40. heat flange area, use vise grip.

If that does not work, try to screw 2 nuts onto that bolt and tighten them against each other, then try to remove.

If that is slipping weld a large nut on that bolt and turn it out with heat.

If that does not work, cut it and driill it out and use a nut, long bolt with lockwashers when reinstalling.

Anthony

 

Heat the housing with a torch with the vise grip on the bolt. The idea is to expand the housing with heat while keeping the bolt as cool as possible as you apply torque.

Paul

 

Thanks guys, propane did the trick! Now just have to retap the thing...

 

High temp anti seize is your friend

 

On all exhaust parts!