Snapped intake manifold bolt

[1jerodjones]

I have a 2002 v6 Lincoln ls. I was replacing the spark plugs and the coil packs and when I was tightening up the bolts on the intake manifold one of the long bolts snapped. I have no idea what to do. Is there any hope for me?? I had my torque wrench set to 89. Please help.

 

[LSinYourLS]

89 FT. LB?! goddam son.

Shoulda had it set to INCH pounds.


EDIT: carefully remove your remaining bolts and the manifold. Get a stud extractor and remove the broken bolt. Go buy NEW BOLTS and set your torque wrench correctly to INCH pounds.

 

[Jim Henderson]

yeow, like the guy said 89 is way too high. That's the torque for lug nuts.

Inchpounds for the future.

An extractor may do the trick. Whatever you do, DO NOT snap off the extractor, they are a beast to remove.

Assuming you know how to use an extractor, go slow and easy and probably use some lubricant. I believe we are working on Aluminum and a steel bolt so maybe this will be easy, assuming you have no corrosion.

Some tricks from other websites, melt a candle into/onto the threads, heat the area, touch with candle. Also gentle heat to the surrounding metal may help.

Use a sharp drill bit to make your starter hole. And Ditto, DON'T SNAP the drill bit.

Maybe get yourself a reverse twist drill bit. Often the broken bolt will twist out while you are drilling the pilot hole.

In all cases, I would use a good name brand USA made extrator or drill bit to decrease your chance of snapping one off.

Depending on whether the bolt sticks out from the hole, you might be able to get a vise grip on it.

Last resort other than taking it to a shop, is you might weld a nut ontop of the broken bolt if there is some sticking out. Don't weld the bolt into the hole, should be an unspoken truth.

Good Luck.

Jim Henderson

 

[1jerodjones]

Thanks rookie mistake with the torque wrench will never happen again.

 

[1jerodjones]

Thanks will have the broken bolt out and a new one in. You guys are the greatest!

 

[joegr]

Thanks rookie mistake with the torque wrench will never happen again.

Just be very glad that you didn't cause much more expensive harm. (Cracked manifold or striped out threads in the block.)
89 in-lbs is less than 7.5 ft-lbs.

 

[FDR]

Just curious... by intake manifold bolts, do you mean valve cover bolts? Holding the valve cover to the cylinder head?

I snapped a valve cover bolt after doing my gaskets because of the same foot/inch mistake. I started using an extractor and thought I was just seeing weird reflections, but the bolt actually spun out with little force. The bolt had been pulled apart without bottoming out.

 

[RigsLS]

What ever happened to the days of tightening a bolt or nut to the point where it gets tight, then followed by a quarter turn?
Hand tight, one finger on ratchet/wrench and only pull as hard as one finger can. Double check a week later.

 

[LSinYourLS]

What ever happened to the days of tightening a bolt or nut to the point where it gets tight, then followed by a quarter turn?
Hand tight, one finger on ratchet/wrench and only pull as hard as one finger can. Double check a week later.

Because that doesn't take into account the static and/or dynamic load a fastener must be subject to without failure.

 

[joegr]

Just curious... by intake manifold bolts, do you mean valve cover bolts? Holding the valve cover to the cylinder head?...

I strongly suspect that he means the bolts that hold the top half of the V6 intake manifold to the bottom half. The top half on the V6 has to be removed to be able to change half of the spark plugs.

 

[1jerodjones]

It was the Air Intake where it bolts to the top of the motor. 8 small bolts.

 

[1jerodjones]

Exactly right!

 

[FDR]

I strongly suspect that he means the bolts that hold the top half of the V6 intake manifold to the bottom half. The top half on the V6 has to be removed to be able to change half of the spark plugs.

Totally unaware of that, sorry. I knew you had to do that in Tauruses amd Escapes with Duratevs, but I thought that was only because of the transverse configuration and lack of room between the intake, head, and firewall.

 

[LS4me]

Totally unaware of that, sorry. I knew you had to do that in Tauruses amd Escapes with Duratevs, but I thought that was only because of the transverse configuration and lack of room between the intake, head, and firewall.

The LS V6 is heavily based on the 3.0L Duratec. Most V6's I've seen no matter the engine orientation have the intake plenum cover one side of the engine.

 

[1LoudLS]

is the V6 narrower than the V8(or a smaller angle of the "V")? I know there is a decently wide valley between the cylinders on the V8, but it does seem like with that intake, its a lot narrower, maybe its just seems tighter because of the fuel rails both going down the center of the motor instead of each side of the intake like on the V8.

 

[LS4me]

is the V6 narrower than the V8(or a smaller angle of the "V")? I know there is a decently wide valley between the cylinders on the V8, but it does seem like with that intake, its a lot narrower, maybe its just seems tighter because of the fuel rails both going down the center of the motor instead of each side of the intake like on the V8.

The V6 is a 60º "V". Most V8s are 90º; as is the 3.9L in the LS.

 

[1LoudLS]

well that would explain it! lol Never knew the angle was so much smaller on the 3.0...

 

[joegr]

well that would explain it! lol Never knew the angle was so much smaller on the 3.0...

It's easier to control vibration to have a V6 at 60° (120° is ideal for a V6, but not very practical). It also works well in that it makes a compact engine for FWD. 90° is ideal for a V8 (720° ÷ 8 cylinders).