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Broken bolt, Any tips? 900 1993

posted by jcooper on Fri Jan 1 17:46 CST 2010
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last visit: Tue Jan 7 22:32 CST 2014

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So I thought it would be a grand idea to replace the paper gasket in my turbo oil return line and was tightening up the second of the two bolts and the bolt head snapped off. Didn't think I was over tightening, but oh well.

I guess my next step is to remove the turbo so I can get access to the bolt to remove it. I have a 93 940T. I believe it is a Mitsubishi TD04 turbo. From what I read in the FAQ, it sound like it shouldn't be too bad to remove (mainly just the center clamp).

If anyone has any advice for what to look out for when I remove it, or any thoughts on what sort of maintenance might be beneficial once I have it off, I'd be very grateful.

I hate to take it out since I have 160K and I've never had any trouble with the turbo (other then the minor oil leak I should have left alone).

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Broken bolt, Any tips? 900 1993

posted by trichard on Fri Jan 1 23:36 CST 2010
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last visit: Fri Oct 24 05:52 CST 2014

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i have this turbo. if you can remove the line and you are lucky there should be a tiny bit of threaded stud left ABOVE the turbo. thread a nut on to it and have some one with a mig welder tack the nut to the stud. it will take one pass and 1 second to do this. no cost to speak of. then unbolt and replace.

no need to remove the turbo.

if the bolt broke flush you can place nut over the stud and fill the nut hold with weld and get the same result.

if you have no welder and have no access to one and you are lucky and have a tip sticking out from the bolt use a VERY HIGH quality vice grips and back it out

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Broken bolt, Any tips? 900 1993

posted by spook on Sat Jan 2 01:10 CST 2010
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last visit: Fri Oct 24 08:06 CST 2014

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Dear trichard,

May this find You well. I'd add to your excellent advice, a suggestion that if a vise-grip pliers has to be used, PB Blaster be applied to the bolt stump and allowed to penetrate. Repeated applications over a couple of days should do it.

PB Blaster will work its way through micro-channels in any corrosion present, and reduce the force needed to turn-out the the bolt stump. The less torque required, the more likely it is the bolt comes out, without the pliers slipping.

I hope this helps.

All the best for the New Year!

Yours faithfully,

Spook

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Broken bolt, Any tips? 900 1993

posted by Volvo From Heck on Sat Jan 2 02:30 CST 2010
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last visit: Mon Oct 13 20:56 CST 2014

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Since the bolt head broke off while tightening, corrosion shouldn't be an issue. With the oil line bolt hole as a guide you may have luck with a reverse direction drill bit--chances are (hopefully) the remainder of the bolt will spin right out. Good Luck--Dave

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