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Valve Cover Studs Broken Deep Inside Housing ... What Now?
The previous owner (or his technician) of my 76 911S must have been lazy or just plain stupid. When I received the car, I noticed some pretty bad valve cover oil leaks. As some of you know, I'm in the process of rebuilding the engine. Upon inspection of the cam housings, I've found that 2 consecutive studs have been broken off deep inside. Instead of removing the studs, they apparently went to Home Depot, purchased some shorter bolts and screwed them in in lieu of the studs.
Now, as it seems that I'm the first caring owner in a succession of clucker after clucker, I'm ready to fix the problem. Anyone have any suggestions on how to get the studs out? I wish I had some pics to show you guys; maybe I can get some later. There isn't much room for error in drilling in the housing. I've thought about purchasing another used housing, but maybe there is an easy way. Tap and Die? Thanks
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1976 911S Targa 3.0 46mm PMOs |
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07-03-2002, 09:29 PM
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Irrationally exuberant
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I would take it to a machine shop. (OK maybe I wouldn't but I would suggest you do.
 ) I find it hard to get that top surface horizontal in the drill press.-Chris |
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07-04-2002, 03:51 AM
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Slumlord
Join Date: May 2001
Location: Canada
Posts: 4,983
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You need to drill down the center of the stud and use an extraction tool. A good job for a milling machine, I wouldn't recommend it be done on a drill press.
I doubt the stud will be tight, it will probably come out easily. |
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07-04-2002, 04:23 AM
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Platinum Member
Join Date: Jul 2001
Location: Leave the gun. Take the cannoli.
Posts: 20,958
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If there are enough threads to screw a short bolt in, I would drill a hole through a short bolt, and use it as a guide to drill the stud for an extraction tool.
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The truth is that while those on the left - particularly the far left - claim to be tolerant and welcoming of diversity, in reality many are quite intolerant of anyone not embracing their radical views. - Charlie Kirk |
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07-04-2002, 05:01 AM
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Slumlord
Join Date: May 2001
Location: Canada
Posts: 4,983
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Excellent suggestion. Have your 'drill guide bolt' drilled in a lathe so the hole is centered and straight, use a nice sharp drill bit and then drive in a square extraction bit. (Use some penetrating oil also)
I don't know if they come small enough but Sears sell a reverse turning (CCW) extraction drill that you could also try, but drill the pilot hole first. They are supposed to grab and extract the screw as they turn. |
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07-04-2002, 05:29 AM
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Registered
Join Date: Mar 2001
Location: Marysville Wa.
Posts: 22,431
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i wonder how they broke deep down in the hole, and didn't hurt the threads above them. hmmm.
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https://www.instagram.com/johnwalker8704 8009 103rd pl ne Marysville Wa 98270 206 637 4071 |
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07-04-2002, 07:14 AM
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Slumlord
Join Date: May 2001
Location: Canada
Posts: 4,983
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Most unusual. Red Loctite perhaps? Still not something I've ever seen. I have seen people drill through a block and put a set screw in as a plug though.
Could it be that the upper part of the hole has no/very little thread left? Stripped perhaps? 
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07-04-2002, 07:24 AM
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The Blue Pheonix
