Urgent help needed: Ignition Coil Bolt Sheared

j_h_cole

j_h_cole

New member
FIXED: Ignition Coil Bolt Sheared

Need advice quickly!

Just a minute ago I sheared off one of the ignition coil bolts during a routine spark plug change (at a relatively low torque). The bolt is sheared off close to flush with the mating surface, making it near impossible to grab with vise-grips, etc.

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How should I extract this bolt?
Where can I get a replacement bolt?
Does anyone know the size/type of bolt?
Can I use a generic one with some spacers as a temp fix?
Will I have to buy an ignition coil to get the bolt (if so anyone have the part number)?

My wife's T4R is immobilized until this can be fixed.
 
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The ignition coil bolts are M6-1.00 x 25mm flange bolts, try to get class 10.9 but class 8.8 will work just the same...

I replaced all mine with SS in the above spec from ace hardware. I'd try there first or a local hardware store that sells individual bolts. Might as well replace them all while you're at it... .
 
i'd first try to drill a shallow blind hole in the center of the sheared bolt and use an easy-out to back it out. This bolt isn't anything special and I'm sure it could be sourced from your local hardware store. Use a bolt from one of the other coils as a reference to gauge how deep the bolt extends into the valve cover.

the coil sits pretty snug inside of the valve cover just by itself. I wouldn't say that your vehicle is inoperable though by any means. You could drive it.

I've seen guys that weld a hex nut to a broken stud in order to back it out. However, not all of us own welders unfortunately...perhaps a local muffler shop would have a small mig welder on hand and they could assist you for a small fee.

A last resort would be to drill a blind hole and incrementally go larger in drill size until you are able to drill out the existing bolt. Then hopefully clean up the existing threads with a tap. Or drill out to proper diameter and use a heli-coil insert.
 
Lol... relax. You can still drive it. Get it all back together and use something (duct tape comes to mind) to hold the coil down until you can get the bolt removed. As long as that coil is and the pressure it makes as it slides over the plug should hold it in place. As stated above, one of those bolt-out kits should back it right out. Get a replacement at a local hardware store and call it good.
 
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Use a Dremel with a thin cutoff wheel to make a slot for a screwdriver.

Tap a prick-punch into the bolt near the edge, then angle it and try to drive the broken piece around to rotate it out.

Mark the center with a punch, then drill and use an easy-out.
 
Before you do anything put something in the spark plug hole so that nothing falls down in there. Even if the plug is still in I'd be worried about metal fragments making their way down in there and then into the engine when you do remove the plug next.
 
Thanks

Hey guys I appreciate all of the replies.

I was able to easily locate some M6-1.0x25mm bolts, grade 10, at my local auto parts store and removed the remainder of the sheared bolt with a bolt extractor from home depot.

Everything is back together and my T4R is running better than ever.

Thanks again for all the help.
 
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