4.6L (1996-2004 Modular) Mustang Technical discussions on 1996-2004 4.6 Liter Modular Motors (2V and 4V) within.

Ok so I broke a bolt

Old 06-08-2006, 01:01 AM
6th Gear Member
Join Date: Jan 2004
Location: United States
Posts: 12,575
Default RE: Ok so I broke a bolt

ORIGINAL: itlnrob


is it one of the bolts holding the plenum down into the intake manifold??

Can you take off whatever the bolt is holding down, and then have some bolt stickingout of the threaded part? Or is it broken off flush??

If it is flush, try using a small screwdriver to back the bolt out. AKA, put the tip of your screwdriver (just one tip of the flat head) on the outside of the bolt and attempt to turn it counter clockwise. You may have to stick at this for awhile. I have seen plenty of broken off bolts come out this way if they are not jammed into the hole or cross threaded.

If you cannot do that, the only other option I know of is to use a easy out. This means you will need a easy out kit, and you will use a reverse drillbit to drill a hole into the bolt. This can be pretty tough if its a small bolt. After you drill the hole you use a easy out to grip the sides of the hole and turn the bolt out.

BTW, it almost sounds like you used the wrong bolt? Are you sure you used the correct length one?
Positive i didn't use the wrong bolt, and yes its the bolt that holds the plenum down to the intake manifold. THat screw driver trick you were saying, How can I turn it if it doesn't have a place for the screw drive, I'm a lil confused about that.

Take the plenum off. then, try to just pick at the broken ridges of the bolt with the screwdriver, attempting to move it in a counter clockwise (out) motion.

I have used this dozens of times at work. As long as the bolt is fairly free when it broke you should be fine.

A EZ out will work if you know wtf you are doing and you don't screw up and drill into the intake.

you MIGHT get away wiht not putting it it back in, on the other hand it might leak....
2000GT4.6 is offline  
Old 06-08-2006, 01:48 AM
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Join Date: Jan 2006
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Default RE: Ok so I broke a bolt

i did the same thing, mistook 88 inch pounds for of 88 ft lb's. take your plenum off...the bolt had at least a half of an inch sticking out, and amazinginly, <b>IT CAME OUT BY HAND</b>

just do it, i was mad at the point, had an extra bolt laying around, same size too, lucky me, and seriously you need to torque the plenum down in a sequence, first at like 5.5 lbs, then 8 lbs.
ackuric is offline  
Old 06-08-2006, 01:53 AM
2nd Gear Member
Join Date: Aug 2004
Location: Phoenix, AZ
Posts: 384
Default RE: Ok so I broke a bolt

if its sticking out, try to cut a ridge in the top of the exposed piece with a hacksaw, then you'll have a spot for your flathead screwdriver to grip...should come right out...this happend to me on a valve cover bolt on my fox
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Old 06-08-2006, 01:54 AM
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Join Date: Apr 2005
Location: Wilmington, NC
Posts: 5,608
Default RE: Ok so I broke a bolt

damn kids setting torque wrenchs to 100ft/lbs on a plenum bolt [:@] jk [8D]
rbstang is offline  
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