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Join Date: Apr 2007
Location: Albuquerque, NM
Posts: 130
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Bolt removal advice

One of the bolts that holds the camshaft housing/valve cover onto the cylinder head of my engine has an allen key tip broken off into the head. To make problems worse, it's one of the bolts that is recessed inside of the housing that is accessed through one of the plugged holes on the cover.

It seems impossible to try and drill the allen tip out and i'm having a hell of a time otherwise trying to get it out.

Can anyone offer any advice on how to get it out?

Thanks in advance.

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Old 07-05-2009, 06:33 PM
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Drill a small hole in the allen bit and drive a sheet metal screw into it, soak it with lube and pull. It might work?
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Rick
93 968 (My summer car),
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Old 07-06-2009, 05:56 AM
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You will need a long drill bit, about the size of the shaft of the bolt you are trying to remove.

Drill at the center of the hex until the head of the bolt pops onto the drill bit.

After removing the cam housing, completely disassemble it and, using a magnet and parts washer, make sure that all of the drill shavings are removed before reassembling.
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Good luck, George Beuselinck
www.944ecology.com
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We buy 944s and sell 944 parts (845-379-1944)
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Old 07-06-2009, 06:11 AM
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Hi, If a common drill bit does not drill a hole you may have to use a cobalt tip drill bit. The hex head broken off inside the bolt is hardened steel, most likely a cheap tool and why it broke off. People always say to buy the best tools you can afford. Really holds true when working on a Porsche. Stanley tools are out, MHO, Snap-on or MAC work great.

Cheers,
Larry
Old 07-06-2009, 10:00 AM
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I can't remember what that looks like down in there, but they may tools to remove bolts with rounded off heads that go around the outside of the bolt that may help some...not sure. One thing to make sure is that you keep the bolts around the bolt with the problem in place. By keeping those bolts tight, it will take the pressure off the bolt with the broken allen wrench.
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Old 07-07-2009, 12:21 PM
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i tore off a bolt when i put my torque tube back on, the easiest method i found was the "easy-out". its basically a backwards drill, you drill a small hole in the bolt and then using the easy out it taps itself into the bolt and back it on out.

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Old 07-07-2009, 03:31 PM
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