Ignition Coil Bolt Snapped, EZ Out broke

[nasdamus]

When i replaced my valve cover gasket a few weeks ago i snapped off one the ignition coil bolts (rusted through). I let it go for the past few weeks (it was dang cold and wasn't going to mess with it) and attempted to use an EZ out last night to get it. Soaked it in PB blaster a couple times the days before, went slow, then bang, snapped the EZ out. It was a cheap Black and Decker one from HD. Nothing is sticking out above the ignition coil base, it's all below surface. I attempted to try and drill it out but nothing was going so i decided to stop and give it a day. Below is a picture of the damage.

any tips on how to proceed? I was going to try to use a center punch on one of the sides and drill a hole and use a punch with a hammer and tap lightly to see if i can get it to move. Otherwise might try to drill out some more or take it somewhere. Any help is appreciated!

 

[Brian3676]

If there is an easy our broke off your turn is pretty much over. Take the cover off and take it to a machine shop, it will be well worth the $20

 

[emoore924]

My first inclination would be to leave it alone. Isn't the coil kind of held in by friction on the plug anyway? If you have a good connection to the plug and you're not getting dirt down in there, it might be ok without the bolt.

If that's not the case, if you pull the coil out is there a piece of the bolt that stands proud of the cover? If so, I'd probably PB blast it, heat that puppy up with a torch, give it an end-on smack or two with a hammer and punch, then see if it will back out with a vice grip.

If you're so inclined, you could weld a nut to what remains of the bolt and try to back it out that way. The shock of the welding heat often helps more than the nut but this usually works.

Or as previously suggested, give up and take it to a machine shop. They'll make short work of it for sure...

 

[nasdamus]

I'd like to just leave it alone, judging by how much it would't budge when i tried to just get the coil off, it ain't going nowhere. The problem is that i also need to change out the spark plugs. If i'd thought about it, i could have just changed that one when the valve cover was off.

I thought about trying to break the ignition coil off. If i did that, i think there would be enough meat left on the bolt to get it out, but then i'd be down an ignition coil and out $50 for a new one.

 

[emoore924]

I thought about trying to break the ignition coil off

I could be missing something but I'm not sure why you'd need to do that. The bolt head that held the coil in is gone. So if you just carefully pry the coil up and off any "stud" that remains from the bolt, you should be able to replace the spark plug, or even the coil if you broke it. Just push the coil back down onto the stud (and therefore the plug) and all should be well with the world.

Help me out, what am I missing...?

 

[Atlanta_man]

Finding a general, small job, machine shop is near impossible these days.
For the past 10 years anyway.

 

[nasdamus]

i think i'm picking up what you're putting down. I tried briefly to pry the coil up last night, but didn't want to push it too hard. It wasn't budging. But you're right, if i can get it up and off, i can get that plug changed and jam it back on there. I'll give it a whirl.

And agreed about the machine shops. I called a couple and they were asking $50-$100 plus are only open odd hours M-F so this would spill into a multi day affair.

 

[kimboy]

How much does a new coil, 6 new bolts (I'd change them all after this event), and a bolt extractor kit run these days?

I'd cannibalize the one coil for the sake of hoping this would be a once and done type of job.

 

[Danger]

Maybe start with a thin, high quality drill bit into the bolt. Then work up in size until it can be backed out with an EZ out?

 

[chitown40]

How about a used valve cover off eBay? i saw the driver side cover for a 4.0 for $30. Dig around or call some junkyards to find a replacement. Then yu can experiment on your old one with some drill bits and such.

 

[nasdamus]

That's a good idea. I did look around just now and found one for $45 shipped (need passenger side), which is still cheaper and i don't need to worry about logistics of dropping it off and getting ride etc.

Update: I was able to use some left handed drill bits last night and get the ez out out. I was also able o eventually get the coil pack off. Now there is still a little bit of bolt to get out, but it's not smooth on top and i'm unable to start a new hole in the middle (picture below, this was after i took what was covering the hole up, remembered at last second to take a pic). I think i might try to cover everything up good and use a dremel and try to make a slice in it and then use a screw driver and see if it'll turn. I soaked it in PB and tried to use vise grips but it wouldn't budge.

It seems like this is perfect for welding a washer and nut to it to try and remove. I've never welded before and that scares the crud out of me.

 

[Slowgoat]

Put heat on it. I apologise if you said that already. Haven't read the whole thread. My trick is I heat one side of the threads only. Not even the whole fastener. It gets the threads to change shape, and gives you a tiny gap to get it moving again. Heat. Penetrating oil. Repeat. It'll come. Be patient.

Glad you got the easy out out. I feel ya on that one.

Hope you get it!

 

[nasdamus]

I think i'll give it a try! Do you just use a small propane torch to do it? Something like this? Bernzomatic UL100 Basic Propane Torch Kit-334458 - The Home Depot

I'll probably add the extension hose so i can move it a little easier.

Also, i was able to grab a valve cover off ebay for $34 so i have some insurance.

 

[emoore924]

Yep, propane will do it. Like I said before... Heat it with the torch. Give it a rap or two on the end with a hammer and punch. Put the vice grips on the end and give it a twist. It'll come out.

Heat, bang, twist.

 

[nasdamus]

Update: Success (on THIS bolt)! Friday night, wire brushed it clean, soaked in PB overnight. Saturday i hit it with the torch for 30 seconds, let it cool for 5 minutes. Gave it a couple of light taps on the different sides with a hammer, soak it in a little more PB for an hour. Repeat. Used visegrips and it turned right out.

When i moved onto the next coil pack the bolt (which i had just had out 3 weeks ago) snapped flush with the valve cover. I was able to progress through 4 drill bit sizes and (like a dummy) tried to use a different set of EZ outs, same result. Stupid. Now it's flush with the VC. I already got another cover of ebay and will swap them later this week if nothing else. I'm going to try to get this one out with a dremel pointy bit.

If i have to swap Valve Covers, can i reuse the new VC Gasket i just installed 50-100 miles ago? Obviously if it gets stuck or breaks or anything i'd have to replace anyways, but otherwise?

 

[chitown40]

Yep, you can reuse the valve cover gasket if it is intact.