Broken Cylinder Head Bolts

[GeoJeep]

Wow, this past weekend has been a process for sure. We found out that we either have a cracked cylinder head or just a bad head gasket. So after attempting to remove the cylinder head on my sons 2001 TJ with the 4.0 we accidentally cracked two cylinder head bolts, stripped one and stopped with the last one we could not loosen. After a few hours of internet searching, it appears that the broken bolts have to be tapped, drilled and removed with a reverse bit. The issues we are having is that one stripped head is against the firewall and the other snapped bolt is across from it along the firewall providing us with no good overhead access to reach them. We did pre-soak them with PB blaster but it seems that the lubricant did not get all of the way down because of the high torque specifications on the bolts.

Can anyone provide some specific guidance on how to remove the bolt with the stripped head and the other two that have snapped? Both snapped bolts are broken about 2/3 - 3/4 of the way down in the cylinder and I do not have any of the extraction tools (yet). I believe I may have to get some, but advice on what ones to use to get that far down as well as how to get good access to them being against the firewall with no real headroom is greatly appreciated. Do I have to find a right angle drill attachment, pull the engine to get to the two areas or are there other ways? We really cannot afford the tow to a shop and the high hourly rates to help with this. He has to get back to school so we only have two more weekends to get this accomplished. Thanks all in advance!

 

[macleanflood]

Can you remove the bolt head and remove the head entirely? Most likely once the head of the bolt is removed the bolts will come right out.

You're not too far from pulling the engine.

You also could get more room removing the motor mounts and lowering the engine or disconnecting the transmission mount...you probably already have the skid off...and rasing the transmission.

-Mac

 

[mrblaine]

Can you remove the bolt head and remove the head entirely? Most likely once the head of the bolt is removed the bolts will come right out.

You're not too far from pulling the engine.

You also could get more room removing the motor mounts and lowering the engine or disconnecting the transmission mount...you probably already have the skid off...and rasing the transmission.

-Mac

There are two weekends to get this done and we don't know if there is a head sitting there ready to go on in case it isn't "just" the head gasket.

 

[GeoJeep]

Can you remove the bolt head and remove the head entirely? Most likely once the head of the bolt is removed the bolts will come right out.

You're not too far from pulling the engine.

You also could get more room removing the motor mounts and lowering the engine or disconnecting the transmission mount...you probably already have the skid off...and rasing the transmission.

-Mac

Thanks for the advice. I did not remove the trans mount but we do want to replace the motor mounts so this can help us with access - I hope.

I may be able to cut off the stripped bolt head and the stuck bolt head with a grinder then get some kroil on them to hopefully loosent them.

 

[macleanflood]

Those head bolts... we've had a couple of discussions about whether they're 13mm or 1/2" 12 point. Some sockets just fit better than others.

-Mac

 

[mrblaine]

Those head bolts... we've had a couple of discussions about whether they're 13mm or 1/2" 12 point. Some sockets just fit better than others.

-Mac

They would never be anything 13mm since they are an SAE fastener. Regardless of how various shit sockets fit, it is still a 12 point SAE so if your 1/2 doesn't fit, find one that does. This is a socket problem, not a fastener problem.

 

[GeoJeep]

the 12 pt craftsman socket does fit. #1, we
broke it while trying to unbolt the head and had to get a new one. And #2, one of the bolts head is not stripped. I believe I may be able to cut it off and then when the cylinder head comes off, I can get some lube down there to loosen it.

 

[macleanflood]

How much rust and corrosion are we talking about? How's the frame? You may be saving the beating heart of a dying patient...

How'd the exhaust and intake come off...easy or was that also a fight?

-Mac

 

[GeoJeep]

How much rust and corrosion are we talking about? How's the frame? You may be saving the beating heart of a dying patient...

How'd the exhaust and intake come off...easy or was that also a fight?

-Mac

It's all in great shape. We bought a frame off a guy in Ohio that boxed, welded and coated it and had it put under a body that had new floor plans and rails welded in. Also, it's kind of a sentimental thing for my sone to have this Jeep so the more can save on this throughout the process the better. We have had no issues with removing the intake and exhaust manifolds. We are also replacing the motor mounts.