EGR pipe troubles

[Algypan]

Right, the cursed van is at it again... After spending the last week tidying up various leaks and stains with the trusty brake cleaner to find the sources, I have ran into another issue....

I noticed one of the bolts behind the EGR pipe(?) was soaked in oil. I thought right away that the joint might have split at the flange and it's leaked onto the bottom bolt. I went to take it off from the rear of the engine first and one of the bolts snapped off. This is now what I'm left with...

Anyone know how to get this off without absolutely chewing up what is left protruding? I'm thinking the smartest thing is to book it in and get the garage to weld a nut onto it, but wasn't sure if there was something I could try first? Also what kind of bolts are they? They have a nut on but nothing the other side.

 

[iancellis]

Is it a bolt or a stud, either way the pipe will need to come off then possible a stud extractor may work after a good soak in penetrating oil, if that fails a lot of local heat and cold to loosen it up will be next line of attack, if that fails you last options will drill it out and use extractor to wind out or weld a nut on and and try and wind it out this way , from previous issues like this its going two way easy or a lot of swearing

 

[iancellis]

my son has a evo 8 and a 94 mini which we have stripped done endless time anything exhaust / heat related are usually a nightmare, if you go down the the road of heating use mapp gas , pluming propane mix is to cold and some seized release spray will give you the cold . good luck if you can do it yourself.

 

[Algypan]

Is it a bolt or a stud, either way the pipe will need to come off then possible a stud extractor may work after a good soak in penetrating oil, if that fails a lot of local heat and cold to loosen it up will be next line of attack, if that fails you last options will drill it out and use extractor to wind out or weld a nut on and and try and wind it out this way , from previous issues like this its going two way easy or a lot of swearingView attachment 277811

Ooh, where can I find this tool?

Luckily the pipe is still secure. I'm off to buy some penetrating oil so I can tackle it when I'm off next week

 

[noggin]

These are quite handy if you have a bit of stud protruding.

https://www.cromwell.co.uk/shop/hand-tools/stud-extractors/stud-extractor-drive-1-2in-chrome-alloy-steel/p/KEN5826760K

 

[iancellis]

google sealy stud extractor , thats prob a m10 thread so make you get the size that fits m10, soak both sides as the other will prob go the same way, or if you have two nuts try locking these together on thread and unloosen that way, this is where the disclaimer comes into effect and your swearing starts, if this fails do you access to a welder or tools to drill out what left of stud, as you might end up taking manifold off at this point get a jcb as now you are starting to dig a very big hole for your self, just a warning it can go wrong really quickly

 

[Algypan]

Ok, by some miracle I have managed to get an m8 nut on there to catch the thread after I tried to tidy it up. I didn't go ham on tightening it too much. So I'm thinking I should spend the next week giving it a little penetrant a couple of times, then seeing if I can get the other nut off. Once the pipe comes off it will expose more thread and then I think I will try the 2 nut method.

Any ideas if those shitty little studs come as parts? Or is it a case of just any m8 stud, cut to size and sling a nut on it?

Thanks for all the suggestions!

 

[DaveD]

Ok, by some miracle I have managed to get an m8 nut on there to catch the thread after I tried to tidy it up. I didn't go ham on tightening it too much. So I'm thinking I should spend the next week giving it a little penetrant a couple of times, then seeing if I can get the other nut off. Once the pipe comes off it will expose more thread and then I think I will try the 2 nut method.

Any ideas if those shitty little studs come as parts? Or is it a case of just any m8 stud, cut to size and sling a nut on it?

Thanks for all the suggestions!

Agreed, get some penetrating oil on it every day until you make any attempt on it. Do the other nut at the same time.

 

[iancellis]

Studs are usually threaded both ends and an un threaded piece in middle ,type in search box on forum there is a post on sizes, soak thread for a while, then if the good size is tight work it slowly both directions loosen a bit then tighten a bit to reduce risk of snapping, and repeat on broken side with two nuts

 

[Algypan]

Agreed, get some penetrating oil on it every day until you make any attempt on it. Do the other nut at the same time.

It was lucky that under the nut had two washers, which is what left just enough thread exposed to get a new nut on it. Does that count as being lucky still??

 

[FerrisBFW]

Ok, by some miracle I have managed to get an m8 nut on there to catch the thread after I tried to tidy it up. I didn't go ham on tightening it too much. So I'm thinking I should spend the next week giving it a little penetrant a couple of times, then seeing if I can get the other nut off. Once the pipe comes off it will expose more thread and then I think I will try the 2 nut method.

Any ideas if those shitty little studs come as parts? Or is it a case of just any m8 stud, cut to size and sling a nut on it?

Thanks for all the suggestions!

I would just go to VW Commercial and order one, it will cost nowt

 

[whodat]

And also added to penetrating oil, a couple of very gentle taps with a 4oz hammer a couple times a day till you've plucked up the courage to go for it.
We are with you.