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Old 11-28-2017, 11:34 AM   #1
wmssbr10
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K04 Install.......broken stud

2010 GTI with 80,000 miles installing ko4. Taking my time also did intake cleaning, timing chain tensioner and motor/tranny mounts. No issues until today. Removing manifold nuts passenger to drivers side and get to last one. Feeling for it and it's not there. Stud already broke . Any thoughts on getting it out? Know what I need to do just not looking forward to it. Attached pics. Can see the blow by on gasket.


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Old 11-28-2017, 12:13 PM   #2
Mk6 Steve
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Screw/bolt extractor.
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Old 11-28-2017, 12:41 PM   #3
APRMK6GTi
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Mine was the exact same stud, I had a shop to extract it out
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Old 11-28-2017, 02:12 PM   #4
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Quote:
Originally Posted by wmssbr10 View Post
2010 GTI with 80,000 miles installing ko4. Taking my time also did intake cleaning, timing chain tensioner and motor/tranny mounts. No issues until today. Removing manifold nuts passenger to drivers side and get to last one. Feeling for it and it's not there. Stud already broke . Any thoughts on getting it out? Know what I need to do just not looking forward to it. Attached pics. Can see the blow by on gasket.


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Did you spray them with pb blaster and let them soak at least overnight?
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Old 11-28-2017, 02:32 PM   #5
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Did you spray them with pb blaster and let them soak at least overnight?


It was already broke. The others come off no issues. Heat shield to turbo out took 1/2 hour. That's what's frustrating. I was prepared for all the issues I've read about with heat shield not this.


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Old 11-28-2017, 02:34 PM   #6
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Mine was the exact same stud, I had a shop to extract it out


So you had it towed to a shop?


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Old 11-28-2017, 02:39 PM   #7
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So you had it towed to a shop?


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I had a local mechanic that did the install, it snapped as he took off the stock turbo. He's done many turbo installs on this car, and he did not put much pressure to unloosen it and it just snapped. He proceeded to install the K04 and put some exhaust paste for temporary. I drove it easy without boost to the shop next day, they extracted it and put in new stud, no problems 30k miles later with track day also.
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Old 11-28-2017, 03:25 PM   #8
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That stud is prone to breaking. And it's hardened steel inside aluminum, which corrodes itself. I installed my turbo without that stud and months later it started leaking. I eventually removed the head to drill it out, which took quite a long time with those expensive carbide bits. There is literally zero way to get it out if it's broke inside the car. Possibly one of those mobile welder people would be able to help, but the head is easy to remove so I just said screw it and did it myself.
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Old 11-28-2017, 04:04 PM   #9
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Mine broke without touching it too, nothing left sticking out. I called a bolt extraction specialist to come carefully drill out it. You don't want to screw up the threads inside the head. Ended up costing me a mere $800. Gave me a reason to go K04, the stock exhaust manifold was slightly warped.
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Old 11-28-2017, 05:22 PM   #10
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If the threads get messed up you can use a helicoil. I’ve used them several times and it works very well! I think I paid $25 for a pack of six.
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Old 11-28-2017, 05:25 PM   #11
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Quote:
Originally Posted by *****2.0t View Post
That stud is prone to breaking. And it's hardened steel inside aluminum, which corrodes itself. I installed my turbo without that stud and months later it started leaking. I eventually removed the head to drill it out, which took quite a long time with those expensive carbide bits. There is literally zero way to get it out if it's broke inside the car. Possibly one of those mobile welder people would be able to help, but the head is easy to remove so I just said screw it and did it myself.
Was there not enough room to use a right angle drill? The head has to be removed?
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Old 11-28-2017, 05:29 PM   #12
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Maybe with some special tools or something. I actually bought a right angle drill for the job and it didnít seem feasible. So I bought valve springs and decided to remove the head. Even with the head off I spent a LOT of time trying to get it out.


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Old 11-28-2017, 05:34 PM   #13
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Damn it! I thought there was enough room with a right angle drill. I’m installing my K04 next weekend and am trying to prep myself for the worst case scenario....
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Old 11-28-2017, 06:53 PM   #14
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My bolt extraction guy got it out with a right angle air drill without taking the head off. Only the turbo was taken out. He hunched over up top and went to work very carefully for about 90 mins. Used a bit kinda like below. End result below that. New stud went right in, no problems.


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