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Re: [T3] Removing a broken stud

On 9 Nov 2001, at 15:28, shackedup wrote:

> I broke off one of the bolts that goes through the heat riser valve thing
> between the heat exchanger and the manifold.  This left a broken stud in the
> heat exchanger.  First I tried to heat it up with a propane torch then
> remove it  with vise grips.  When this didn't work I tried to drill out the
> bolt and failed again.  Now I have the start of a  hole in the heat
> exchanger that is partway over the broken bolt and partway off.  Is there
> any way for me or a shop to get this out?  The engine is out of the car.

With the engine out, this should be relatively easy. You need to 
take it somewhere that has a oxy-acetylene torch. Heat the body 
of the heat exchanger around the broken bolt until it is just barely 
visible as dull red. Let it cool briefly and then drip some heavy oil 
on the stud until it stops smoking. See if you can move it. If not, 
reheat and repeat.

If this doesn't work, remove the HE and heat the whole area around 
the broken bolt and then quickly immerse the whole stub 
containing the stud in a tin can filled with oil; you want to expose 
both ends of the broken stud to the oil while hot.

The stud should now be loose, but it may be staked in place by the 
drilling you did. If that's the case, you may have to remove some 
metal with a moto-tool to free it up.

Jim Adney, jadney@vwtype3.org
Madison, Wisconsin, USA

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