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post #1 of 7 Old 08-18-2019, 01:30 PM Thread Starter
03hemiNorthIL
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broken valve cover bolts

So I was doing head gaskets on my 03 hemi but in the process I broke 7 rusted valve cover bolts in the head. I've tried removing them by using left hand drill bit and the screw extractor but it broke before it removed. So is it possible to re tap the head for the bolts or no?
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post #2 of 7 Old 08-18-2019, 04:56 PM
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Use a little heat to help in the removal process. Just don't fry anything whilst warming up yer nutz .. eerr ...bolts.


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post #3 of 7 Old 08-20-2019, 05:52 PM
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The key thing is if you are going to drill out the entire broken bolt you need your hole to be centered. Be sure to use the proper tap drill size and sometimes with a sharp probe you can peel out the remainder of the bolt. If you must tap it then be cautious, use thread cutting oil and go slow, because if you break the tap off in there if will be even more difficult. A lesson for the future if one breaks don't go any farther without trying something different. First with a flat faced punch tap on the center of the bolt to break it loose without rotating, then turn cautiously, if it starts to move but gets tight again go back the other way and continue to go back and forth and be patient as extracting and or drilling will take much longer. If it doesn't come loose then tap it again a little harder each time. Heat can help but with the valve cover on heat will most likely not get where yo want it to be.
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post #4 of 7 Old 08-26-2019, 05:47 AM
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As aircommuter said, be careful with the heat. You may ruin the covers. Heat the head around the bolt and strike the bolt with the punch to jar the rust. I am curious to see this mysterious "punch tap" though.


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post #5 of 7 Old 08-28-2019, 06:14 PM
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There's Chrysler again, using the lowest quality imported screws they can buy.
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post #6 of 7 Old 08-30-2019, 09:52 PM
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Originally Posted by guyonearth View Post
There's Chrysler again, using the lowest quality imported screws they can buy.
Like they all don't do that.

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post #7 of 7 Old 08-30-2019, 11:23 PM
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Like they all don't do that.
True, but Chrysler in particular seems to have a loooong history of issues with screws breaking that simply should not break. My Dakota had broken manifold bolts that I didn't even try to remove, they just broke on their own. It seems like every bolt on a Chrysler engine is one size too small at least. When you can't get the valve covers off without breaking bolts, something is seriously wrong. I've never broken a valve cover bolt on any vehicle or engine I've ever worked on, and I've worked on engines 65 years old.
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