A Snapped Rocker Cover Bolt can be a frustrating issue, but with the right tools and techniques, it can be resolved. This guide outlines various methods for removing a broken rocker cover bolt, ranging from simple solutions to more advanced techniques.
Identifying the Bolt and Assessing the Damage
Before attempting removal, identify if the bolt is aluminum or steel. This is crucial as different materials require different approaches. Aluminum bolts are more common in newer engines with magnesium blocks. Determine if any part of the stud is protruding from the cylinder head. The visibility of the broken bolt will dictate the best course of action.
Removal Methods for Protruding Bolts
If a portion of the bolt is sticking out, several tools can be used:
- Stud Extractor: A cam lever-type stud extractor, resembling a disc with a hole, can be used. This tool fits over the broken stud and uses leverage to extract it. However, it requires sufficient space around the stud, approximately 1.5 inches in diameter.
- Drill Chuck Style Stud Extractor: This type of extractor functions like a drill chuck in reverse, gripping the stud tightly for removal. While highly effective, these extractors are more expensive.
- Bolt Extractor: A bolt extractor, similar to a socket with deep cutting flutes, can grip the remaining stud fragment. Ensure the extractor is small enough to fit the broken stud.
- Vise Grip Pliers: In cases where the studs are not severely corroded and should back out easily, a good set of vise grip pliers may suffice.
Removal Methods for Flush Broken Bolts
If the bolt is broken off flush with the cylinder head, a different approach is required:
- Screw Extractor: This specialized drill bit with left-hand cutting flutes is designed for extracting broken bolts. First, drill a pilot hole in the center of the broken stud. Then, carefully screw the extractor into the hole in a counter-clockwise direction. The extractor will bite into the stud and extract it as you continue turning.
Preparing for Extraction
Before using any extraction method:
- Remove the Rocker Cover: Remove all other rocker cover bolts and detach the cover to access the broken bolt fully.
- Apply Penetrating Oil: Apply a penetrating oil, such as PB Blaster or Liquid Wrench, to the broken stud. Allow it to soak for some time to loosen any corrosion or rust. This step is crucial even for relatively new engines.
Choosing the Right Method
The optimal removal method depends on the specific situation: the type of material, the extent of damage, and available tools. Start with the simplest methods and progress to more complex techniques if necessary. If you’re unsure, consult a professional mechanic. A successful extraction minimizes damage to the cylinder head and ensures a proper seal when replacing the rocker cover.
