Tapping the threads in manifold for EGT gage and the tap is broke flush with top of manifold. Any Help would be appreciated!

 

well, your lookin at takin the turbo off and then trying to reach it with a pair of needle nose pliers and backing it out. Dad broke a drill bit off in the exhaust manifold in one of his buddys trucks, and he hadda take the turbo off.

 

Yea, you will have to remove the turbo. You will probably have to spray the bolts with some penetrating oil and let it soak a while first. Then you can either use some needle nose pliers and back it out or use a tap to tap your broken tap and pull it out. If that makes any sense.

Once you got the broken tap out you will need to go up to the next size pyro if you want to use the same hole. i.e. 1/8"NPTF to 1/4"NPTF. I guess it is possible to salvage the same hole.

Good luck,
Bob

 

The tap should back right out if it were well oiled going it. Once you get the turbo out of the way, chuck up a very fine quarter inch drive ratchet and find a socket that will just fit the tip of the tap, then oil the stuck tap and work it back out from inside the manifold.

If it sticks, pull the socket off and reach in with a pin punch and carefully tap a flute until the tap starts to turn, then oil it again and go back with the socket. Take your time.

Absolute worst case is that you will have to go after it with a small carbide or diamond burr and a die grinder and simply grind it out of the hole. In thirty years I have only had to go after one with a die grinder, most come right out with a small socket on the tip working from the inside.

 

The cast iron should heat up a lot quicker than the tap if you torch it away from the tap, than you could probably drive it out backwards with a hammer and punch or quality flat screwdriver.

 

And if you are not comfortable removing the turbo there are tap extracters just like easy outs. They have 4 thin legs that fill the space around the flutes of the tap then a wrench on the top to turhn the tap & extractor back out. Again oil well and turn gently. Usually the tap will turn right out with a little care and in the process turn the tap out also. Try Sears or a tool & die shop supplier like Production Tool supply for the extractor.

Good Luck.

 

this is gonna give me nightmares, becasue im gonna install one this weekend. any thing iSHOULDNT do so this doesnt happen to me?

 

Well after awhile of going back and forth on the tap and a little wd-40 she finally came out. I am so relieved. Thanks for all the help!

 

can u still use that hole?

 

O ya just finished putting everything togather and it works! I am so happy now i think i will call it a day!

 

Good news! Now you have a good beer story

Bobby

 

I think tap breakage is rare, you should be fine if you go at it slow, keep the tap greased up good and stay level. The cast is soft, but you still have to back out to break the chips as you go.

 

I wouldn't use grease: Oil will flow, moving the tap chippings away from the tap.

I know some like to use grease to capture the chippings so they don't have to remove the turbo....so, use grease at your own risk

Tony

 

The reason taps usually break are too small of a pilot hole or failure to back the the tap off at least every full turn. If you don't back off the flutes can clog up causing the tap to get tighter and tighter.

 

I used grease when i installed my pyro and it was the easiest part of the install. I kept backing the tap out and cleaning it then regreasing it. I thought the cast manifold seemed like pretty soft cast Iron.