Ok so I managed, like a genius, to break off a bolt inside the valve cover while re-assmebling the recirculating cover after redoing the gasket. It is on the passenger side, the small bolt closest to the front of the car (on the right).

The bolt broke off pretty well level with the top of the "tower" that it threads into.

Is it possible to just fill that hole with all kinds of RTV sealant once the recirc cover is back on, or is the bolt absolutely necessary?

Thanks!

 

My thought is that if you did not need it it would not be there at all. Not what you wanted to hear, but .....

 

You could try to use a punch or small chiesel and try to back the rest of the bolt out, or you can get a set of easy outs their a drill bit and remover together in different sizes that drill in a conterclock wise direction allowing you to grab the broken stud and back it out. Just a suggestion.

 

I think Im going to head to the store and try to get some easy-outs and hope that works. Only bad thing, chrysler doesnt have the bolts in stock so I have to rent a car for a few days until the bolts come in. For what is probably a $1.00 bolt. Lol.

 

Once you have it out you can replace it with a similar metric bolt until the factory replacement comes in. ... your going to be at the hardware store anyway.......

 

You busted off the bolt, now things go slower.

First the removal is not hard but it is often slow, if you can handle that lets start. You need a dremel tool and enough room to position it WITHOUT FIGHTING other objects.

You need to cover everything with two layer of towels that is dirt sensitive. You need to have a small enough bit to cut a hole into the broken off bolt. THis requires a GREAT drill bit or a small carbide cutter. I use the carbide dental cutters from root canal work cause I got them from my dad and they make a nice hole in even hardened bolts. Most screws and bolts are soft in the center.

You get a hole like 0.04 or so depending on the bolt size and I think your using a 6mm bolt. BTW replace all of the bolts with hardened ones so that this does not occure again. When you have the bore hole you can get a tiny easy-out which is s left handed screw thingggy that engauges the hole and tightens and backs out the spent bolt.

Not hard work, requires you to have a dedicated train of thought and a good understanding of the process, you do wanna be in the center of the bolt as the other part is soft aluminum and will cut very fast - uuughh.

I have done this many times and it is not a speed contest, and you dont run the dremel fast like 1/3 speed max as you wanna cut carefully in the center. SOme of the repairs of broken bolts amazed others, key is the can do attitude and patience.

Go gett em tiger and let us know how it goes.

RTV works for a short time, but messy

Woody on weekend time..........
Patience - Wikipedia, the free encyclopedia

 

those bolts purpose is to hold the cover in place while the sealant dries. at this point i would pull off the valve cover and use a reverse drill bit to try and get the broken (aluminum) bolt out and replace with a stainless bolt, they are m5 bolts.

 

Hi, A newbie here.Done exactly the same to mine about a month ago.Hand tightened bolts,waited for rtv to set and then gave the bolts a final tweak and SNAP!!.
Thought about drilling a hole through the bolt with a dremel and then trying to unscrew with a watchmakers screwdriver ,but have left it as it is with no problems.I will worry about it the next time the covers need sealing again.

 

Ok went to home depot, got a #1 extractor, proper size drill bit (2 mm), and two replacement steel bolts. Took my time, thank God the extractor worked, and the broken bolt came right out. Spent a few hours sanding off the sealant I put on it, resealed it, set it, and the new bolts went in just fine.

Thanks so much for the help and advice everyone!!!! Love this forum!

 

No problem, whats the address for the invoices?
Taking it out was the best move, easier now than later if it leaked.