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[font=Arial, Georgia, "Times New Roman", Times, serif]Okay back on topic here I have good news! The dismantling phase is over!
[font=Arial, Georgia, "Times New Roman", Times, serif]On these 302 engines there are 4 bolts that go through the timing cover and[font=Arial, Georgia, "Times New Roman", Times, serif] into the engines water jacket. These 4 bolts are famous for being a PITA because they touch the coolant inside the e[font=Arial, Georgia, "Times New Roman", Times, serif]ngine the threads get quite corroded and they will snap off at timing cover or engine block when you try to rem[font=Arial, Georgia, "Times New Roman", Times, serif]ove them.
[font=Arial, Georgia, "Times New Roman", Times, serif]On our 104K donor engine here we were lucky, only one of the bolts broke.
[font=Arial, Georgia, "Times New Roman", Times, serif]So it is my job to extract the broken stud.
[font=Arial, Georgia, "Times New Roman", Times, serif]Over the years I have had to battle many of these both on the engine stand and sometimes in the truck, they can[font=Arial, Georgia, "Times New Roman", Times, serif] be a real nightmare.
[font=Arial, Georgia, "Times New Roman", Times, serif]Here is my method for extraction:
[font=Arial, Georgia, "Times New Roman", Times, serif]First CLEAN the area, clean all threads that are[font=Arial, Georgia, "Times New Roman", Times, serif] visible and all debris from the area, I use a wire brush
[font=Arial, Georgia, "Times New Roman", Times, serif]Then SOAK the bolt head and surroundi[font=Arial, Georgia, "Times New Roman", Times, serif]n[font=Arial, Georgia, "Times New Roman", Times, serif]g area with PB blaster, unicorn tears, or whatever lubri[font=Arial, Georgia, "Times New Roman", Times, serif]cant you favor.
[font=Arial, Georgia, "Times New Roman", Times, serif]Next CLEAN the area again
[font=Arial, Georgia, "Times New Roman", Times, serif]Now its time for the blue wrench (Torch), the purpose here is to heat the bolt as much as possible without getting the engine block too hot
[font=Arial, Georgia, "Times New Roman", Times, serif]When the bolt gets really hot it will expand and hopefully break the bond the corrosion has on the threads.
[font=Arial, Georgia, "Times New Roman", Times, serif]Let it cool down! No point it trying to turn the bolt while it is expanded and hot (tighter in the hole)
[font=Arial, Georgia, "Times New Roman", Times, serif]Next we find a nut that kind of fits the remaining threads and using lots of heat with the mig welder, h[font=Arial, Georgia, "Times New Roman", Times, serif]opefully weld the nut to the exposed bolt bit
[font=Arial, Georgia, "Times New Roman", Times, serif]CLEAN the tip of the exposed stud, bare metal is what we are after here for a good weld
[font=Arial, Georgia, "Times New Roman", Times, serif]Smack the stud with a hammer to hopefully jarr any corroded bits off of the threads (break the seal)
[font=Arial, Georgia, "Times New Roman", Times, serif]Attempt 1, failed
[font=Arial, Georgia, "Times New Roman", Times, serif]Attempt 2, failed
[font=Arial, Georgia, "Times New Roman", Times, serif]The nut just twists right off, not enough heat in the weld[font=Arial, Georgia, "Times New Roman", Times, serif]to grab the broken stud., not enough room to get the tip of the mig welder in the hole.
[font=Arial, Georgia, "Times New Roman", Times, serif]So the next approach is to use a piece of flat stock with a hole drilled in it. CLEAN the area to be welded, bare[font=Arial, Georgia, "Times New Roman", Times, serif]metal. DO NOT USE BRAKE CLEANER
[font=Arial, Georgia, "Times New Roman", Times, serif]Many people do not realize when you clean metal parts[font=Arial, Georgia, "Times New Roman", Times, serif]with brake clean that are to be welded the brake cleaner can produce a toxic gas. So we use acetone or alcohol,[font=Arial, Georgia, "Times New Roman", Times, serif]even just soap and water.
[font=Arial, Georgia, "Times New Roman", Times, serif]I added a little bit of metal to the top of the broken stud, placed the flat stock over the broken stud and make a nice weld all the way around.
[font=Arial, Georgia, "Times New Roman", Times, serif]Let it cool! a little bit of cold water on the w[font=Arial, Georgia, "Times New Roman", Times, serif]eld will only help you here.
[font=Arial, Georgia, "Times New Roman", Times, serif]That did it! The flat stock gave us the weld we needed and the leverage to get the stud turning. Work it back an[font=Arial, Georgia, "Times New Roman", Times, serif]d forth slowly, more PB blaster
[font=Arial, Georgia, "Times New Roman", Times, serif]and finally....unthread the broken bit!
[font=Arial, Georgia, "Times New Roman", Times, serif]SUCCESS
[font=Arial, Georgia, "Times New Roman", Times, serif]Now the last bolt is out
[font=Arial, Georgia, "Times New Roman", Times, serif]The build up can begin..........
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I know my crazy! Do you?
2007 Sport 4door 4x4 4.0L SOHC V6 Ranger