I had done my research, or so I thought. When I started drilling I drilled into the center of the manifold, above the turbe, I am about a 1/8" in and still not through, in the middle of the manifold, is their a piece that sperates each side? If so, can I go to the left (towards the cab) and put another hole. I hope I put it in the right spot... Help please,

year 04.5.

 

5/64" is the size bit I am using

 

Not sure if yours has a center divider but the manifold is close to 3/8'' thick.

 

Can I abandon said hole and changge the location?

 

Are you drilling it in the collector, where the two sides come together? There is a center brace in it... you'll never get through it.

You have to drill in the pipe part.

As long as you have not broken through I guess you would be ok, just depending on how much you have left.

 

The more I look at it, I am worried the egt probe is to long and will sit against the other side

 

You should be able to adjust the probe insertion with the fitting it passes through.

 

Well, it just got worse, I drilled the second hole (pre turbo), and when I finished with the pilot hole, and backed out the 5/64 bit, it broke off in there. I went ahead and drilled the hole for the probe and tapped it, what should I do now? Will the turbo survive if I start it, or am I going to have to take things apart and get it out of there, thanks.

 

I am not an expert on this but I would take the turbo off and get the piece of drill bit out of there.
If someone who knows differently says leave it in there take their advice.
I know parts of the turbo are delicate and the last thing I would want is a part of turbo knicked enough to cause it to be imbalanced.

 

This is where its installed (not my pic, this is thanks to fisherguy)

 

You broke the drill bit off inside the exhaust manifold? Time to take it off and get it out if there.

I can only imagine the carnage of a piece of drill bit falling into the exhaust wheel...

Get some PB blaster, spray the bolts on the turbo for a day, then drop the turbo/pull the manifold.

Dang it, boy.

 

DO NOT start engine I repeat DO NOT start engine turbo will be permanently ruined . there is not enough space for it to clear
think sticking a finger in a fan. the hardened steel drill will chew up the fine cast turbo and cause the shaft to bend and that side to become well just junk then the turbo parts will just rattle around in your exhaust all the time till you drop that as well

 

Thank you guys for the help... when I go to pull the manifold, will I have to pull it from the engine, or just where it bolts into the turbo? Obviously I am not much of a mechanic.... If I have to pull it off the engine too is their anything I should be mindful of?

 

How much work is this going to be?

 

if your lucky you can remove the turbo only and use a light an pliers an pull the drill bit out from inside the turbo or use a mirror and see up into the manifold and carefully pull the drill out from the inside then you may not have to pull the manifold off
if so you will need new exhaust gaskets and start from the rad end first one manifold bolt at one end then one at the other end back and forth till thier all off