Rusted Bolt Removal Tips Needed

[LorenS]

I'm putting this here because it doesn't apply to any limited Generation of truck.

 

Am attempting to remove the exhaust flange bolts from my turbo "about" so that I can in stall my new exhaust. 

 

I have been spraying it off and on for weeks, both cool and hot, with AeroKroil. Today I've laid into it both from above and below with my wimpy air hammer in an attempt to jostle the rust. My guess is that from the top was a mistake, as it could swell the bolt like a river. However, the other attempt from below didn't make much difference.

 

Any further in-truck ideas?

[IBMobile]

Heat with oxy-acetylene torch, red hot, but don't melt the metal.   Heat the flange area, that will expand the hole and brake the rust bound from the bolt. 

[LorenS]

Considering how difficult it is to reach the other bolt with a torch - and my experience level with a torch - this will be an out of vehicle repair!

[NIsaacs]

Dang, that rust looks brutal. Is that the 5 bolt elbow? What do the bolts look like? Is it possible to remove them instead? 

[That Guy]

Looks like you have hit it with a center punch. I drill them out just shy of the threads, then cut the end twice to make an X pattern, then tap one or two of the tabs in and it should almost fall out. 

 

I should say, if you get just shy of the threads, it may back out anyway as it has some give to it.

 

Short of that, heat and your prefered penetrant. Heat it up, spray some in, tap with hammer, work back and forth until it starts to work out. That works about half the time. 

 

Rust... well, iron oxide, is roughly 10 times the size of the base metal. So, 1mm of iron can create 10mm of rust.  It is easy for that to lock it in so tight it will never come out. At least in this case, it isn't a blind hole.

Edited October 3, 2020 by That Guy

[Max Tune]

If you don't have access to welding torches, mapp gas is your next best bet. Can be bought anywhere and will get the metal much hotter than propane. Like was said, get it cherry red hot and try to work the bolt while hot. Rusty bolts in cast iron are never fun. Good luck.

Also, don't try to muscle it out, finesse is needed.

[Blueox01]

14 hours ago, LorenS said:

Considering how difficult it is to reach the other bolt with a torch - and my experience level with a torch - this will be an out of vehicle repair!

Loren, Unbolt from turbo, get turbo off then that pipe will drop down and you can cut the bolts in front of the flange. Then you can heat and work them loose.

[LorenS]

19 hours ago, NIsaacs said:

Dang, that rust looks brutal. Is that the 5 bolt elbow? What do the bolts look like? Is it possible to remove them instead? 

It sure is, and they are possibly even worse. I bought a used 5 bolt elbow so that if I install a different turbo I don't have to worry about this one.

 

All the turbo to manifold nuts came loose okay, so are now Anti-siezed. However, one of the oil drain line bolts is stuck, too!

[That Guy]

On the oil drain, heat seems like the best bet.

 

 

I have been wanting one of these for a while. 

 

 

 

[LorenS]

It sure would be a cool tool to have! I'd have to get creative to get near the bolt.

10 hours ago, Blueox01 said:

Unbolt from turbo

I think those bolts are even worse!

[Dieselfuture]

Cut top of the studs flush with flange then heat the flange and good luck

[That Guy]

Used to be able to heat up bolts and screws and blow them out with the gas axe without harming the surrounding metal.

 

I haven't don't it in long enough I wouldn't trust myself, but, you could heat the head of a bolt in the same manner and them back it out. Just don't hit the oxygen lever.

[Mopar1973Man]

First I would hose that with spray lube of some sort, PB blaster, etc. Typically I would reach up from the bottom with a impact gun and hit the trigger for a short burst in remove, and then rewverse and drive it back in. Then reverse and again to remove. Each time rocking the bolt back and forth brings a bit of lube to the threads. Growing slightly longer runs each pass. Might add more spray too as I go depending on the bolts. Not broke any bolts there yet. Just did a 4" inch diamond eye exhaust for local gal with a 2001 Dodge. Impact gun is a key part of success its the hammering that helps when straight pull with a ratchet will typically break the bolt. 

Edited October 4, 2020 by Mopar1973Man

[LorenS]

2 hours ago, Mopar1973Man said:

First I would hose that with spray lube of some sort, PB blaster, etc. Typically I would reach up from the bottom with a impact gun and hit the trigger for a short burst in remove, and then rewverse and drive it back in. Then reverse and again to remove. Each time rocking the bolt back and forth brings a bit of lube to the threads. Growing slightly longer runs each pass. Might add more spray too as I go depending on the bolts. Not broke any bolts there yet. Just did a 4" inch diamond eye exhaust for local gal with a 2001 Dodge. Impact gun is a key part of success its the hammering that helps when straight pull with a ratchet will typically break the bolt. 

I agree with the impact, it's one reason I tried the air hammer with the "Shake and Break", or whatever it's called.  It the device you put in the air hammer with a 1/2" socket drive on the other end, then can rotate with a standard wrench.  Since those are flanged bolts, I really thought it might work.  I've been spraying those bolts for weeks with Aerokroil penetrant.  However, on the outboard bolt the rust has - for lack of a better term - welded itself solid.  As in, I can't see the gap between the thread and the flange!  It's like I used rust brazing material.  Maybe if I had borrowed a bigger air hammer it would've worked better, I could only find my wimpy, rapid-firing one.

 

I think the next step is to work on the oil drain bolt so I can remove the entire turbo from the truck.  I haven't made any headway with @Threadzy's HX35 he sent to me (other than getting it all taken apart), so I need to be able to reuse the HY35 the same day it comes out of the truck.  Since I'm still stuck at home recovering/quarantining from the Commie Cold, I have time on my side but it also means I can't get any help!

[Threadzy]

You said your replacing the exhaust? I’d just cut the pipe with a sawzall and pull it and the turbo out together. Then work on it from a bench. 

[That Guy]

You should be able to take the turbo off with the drail line attached. It slips into a little silicone hose behind the oil cooler. Should just have a little worm clamp holding it. Just take the exhaust off and pull the whole thing up. 

 

That is assuming that the hard line loos like so.

https://www.genuinedieselpart.com/products/turbo-oil-drain-tube-5-9l-24v-cummins-dodge-94-02

[LorenS]

6 hours ago, That Guy said:

take the turbo off with the drail line attached

I didn't know that's how it is attached, that's great news! Maybe next weekend I can tackle this project.