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Snapped bolt going into turbo

Discussion in 'A4/S4 forum(B5 Chassis)' started by steady jay, Apr 29, 2013.

  1. steady jay
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    steady jay Member

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    [Apr 29, 2013]
    Basically I was fitting the decat 1st thing yesterday morning so I was half asleep and snapped the bolt that connects the cat to the turbo, I've got about 2-3 mm of thread sticking out of the turbo. Could that be drilled out or does it have to go to turbo specialist. I'm not looking to spend a lot as the penny valve is f**ked. I plan on getting a beach buggy hybrid in the summer.

    Unless someone has a spare k03 knocking about for cheap just need it fixed before 5th of may because I really had my hopes up for BHP show on the 6th.

    cheers jay
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  3. JudderMan
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    JudderMan Active Member

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    [Apr 29, 2013]
    Can you get a hacksaw/angle grinder in there? If so you might be able to cut a groove get a flat blade in there. You've only snapped a bolt so no need to get a turbo specialist on the case. There are loads of bolt extractor type tools though available. Check eBay.
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  4. steady jay
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    steady jay Member

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    [Apr 29, 2013]
    That's a bloody good idea mate. I'll give the angle grinder a go. Cheers
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  5. JudderMan
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    JudderMan Active Member

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    [Apr 29, 2013]
    Don't go too far into it and crack the turbo housing, though ;)
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  6. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Apr 29, 2013]
    Why not try wind a nut on the exsisting thread and welding it to the stud then use a socket or spanner to try and remove the stud ??
    #5
  7. steady jay
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    steady jay Member

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    [Apr 29, 2013]
    That would be the easiest option if I had access to a welder
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  8. boost-addict
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    boost-addict Member

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    [Apr 29, 2013]
    were are you located steady? im in sevenoaks, and have a welder, your likey lightyears away some were up north!

    also thinking if i work the weld in both sides of the nut then imediatly turn it off the heat should be enough aswell. i got some plusgas (decent penetrating fluid)

    so if your not far ill be glad to help. i also have a k03 that id lwt you have but the bearings have siezed and its destended for a hybirid any how!

    also i fitted a decat so can give you hand on that front. but i must warn you the car become very raspy down low and drones alot, but then i only have a single rear box, 2.5" system made up by me, need another one if i can
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  9. steady jay
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    steady jay Member

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    [Apr 29, 2013]
    Hi mate I'm in Welwyn garden city, Hertfordshire not a squillion miles but still a good hours drive. Not too bothered by the drone already have a 2.5" milltek non res. my last a4 had 2.5" custom with decat but with stock d/p which was much quieter. Think I've not got enough time to get all the things done before BHP show. Still have forge map sensor and all new red silicone hoses for fmic to fit and a passenger door I got from the scrappy. "Yeah right" says mrs steady jay
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  10. boost-addict
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    boost-addict Member

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    [Apr 29, 2013]
    yer 60 mile! even if you hire a small mig or arc welder for the say its like £40/50 cheaper then a turbo guy or a garage
    #9
  11. steady jay
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    steady jay Member

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    [Apr 30, 2013]
    How can I find the part number of the bolt I snapped? I went into audi in Watford and got completely ignored for half hour so I'm f**king fuming. my local vw/audi independent shop said its main dealer only so I'll give vw a go which round the corner, if I can get the part number.

    thanks jay
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  12. AR-rkon
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    AR-rkon BZZZZ.... caffeine fueled electrical engineer Regional Rep

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    [Apr 30, 2013]
    think the part number is N 0445203 its an M10x28 Stud... :arco:
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  13. steady jay
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    steady jay Member

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    [Apr 30, 2013]
    Can I get away with just using the correct size stud? Instead of using the proper one that has 2 different direction threads.
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  14. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Apr 30, 2013]
    You could just use a stud thats a similar size and thread even if its slightly longer than the other 2 so long as it doesnt hit the cat.
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  15. steady jay
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    steady jay Member

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    [Apr 30, 2013]
    It's decatted so nothing to hit really, think I could just stick 2 nuts on the end so there no chance of working itself out
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  16. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Apr 30, 2013]
    One nut should be enough.
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  17. steady jay
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    steady jay Member

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    [Apr 30, 2013]
    Ok fair enough cheers :)
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  18. adamss24
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    adamss24 Well-Known Member

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    [Apr 30, 2013]
    #17
  19. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [Apr 30, 2013]
    You could even knock the thread closet to the turbin housing just to stop it coming loose with a centre punch.
    #18
  20. AR-rkon
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    AR-rkon BZZZZ.... caffeine fueled electrical engineer Regional Rep

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    [May 1, 2013]
    #19
  21. aragorn
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    aragorn "Stick a V8 in it!" Staff Member Moderator VCDS Map User

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    [May 1, 2013]
    turbo to downpipe studs are M10 i think, certainly bigger than M8!
    #20
  22. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [May 1, 2013]
    M8 are probably the manifold cylinder head studs.
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  23. steady jay
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    steady jay Member

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    [May 1, 2013]
    Got some from vw in the end, hasn't helped though that snapped one is pi**ing me off now!
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  24. boost-addict
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    boost-addict Member

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    [May 1, 2013]
    have you not tried putting another nut on there?
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  25. steady jay
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    steady jay Member

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    [May 2, 2013]
    Can't do much with it though, I'm rapidly running out of time so I might whip off the whole turbo and carefully drill it out.
    #24
  26. Bradderz_1988
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    Bradderz_1988 Dont replace it, Upgrade it !!

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    [May 2, 2013]
    Maybe try getting some heat on the stud and try removing it with vise grips if theres enough thread to grip on to. I had to have mine redrilled and tapped cost me £40 from my works local engineers shop.
    #25
  27. Blue_Thunder
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    Blue_Thunder Active Member

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    [May 2, 2013]
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