Intake manifold removal problem

xA2D9 · Aug 10, 2016

I'm actually getting to get to the valve cover gasket on my 01 2.3l DOHC. From what I understand there are supposed to be 5 10mm bolts for the intake, which I have located but that's where my problem is. This vehicle was up north for.... Probably it's entire life so everything is rusted and the bottom three bolts are no longer 10mm and are rounded, 8mm way too small and a 9mm will fit but can't grab, I've tried those socket bolt extractors but I can only find 8mm and 10mm so it won't fit, I just tried jb welding a 9mm socket to it but won't stick to that surface very well. I'm running out of ideas because of my lack of room to do anything so any ideas would be greatly appreciated. Thanks.

adsm08 · Aug 10, 2016

Snapon sells a set of turbo sockets. It is salty, around $200, but they go from 5mm to 13 or 14, (I think) in tenth mm increments. There will be one in that set that will grab those bolts.

MagicMexican · Aug 10, 2016

If you're gonna pay $200 for sockets... I'd look into getting another plastic manifold from a junkyard, then cutting yours out with sawzall. Once you do that, then you'd have room to use a vice grip or drill it out or whatever method you want. And then you'd be left with a huge mess of plastic sawdust to clean up with a shopvac so your engine doesn't beathe it in later lol.

edit: is that one plastic? I'm not familiar with the 2.3L, but the one in my 4.0 is plastic.

Teddlet · Aug 10, 2016

Don't know what the torque is on those bolts, but do you have access to try to put a slot in the head with a dremmel sort of tool, & then use half a can of PB blaster with a large screw driver? Or else cut/file/grind off enough to make the 8mm gripper fit?

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xA2D9 · Aug 10, 2016

MagicMexican said:
If you're gonna pay $200 for sockets... I'd look into getting another plastic manifold from a junkyard, then cutting yours out with sawzall. Once you do that, then you'd have room to use a vice grip or drill it out or whatever method you want. And then you'd be left with a huge mess of plastic sawdust to clean up with a shopvac so your engine doesn't beathe it in later lol.

edit: is that one plastic? I'm not familiar with the 2.3L, but the one in my 4.0 is plastic.

It is the plastic one and I was just thinking about doing that and picking up a new/junkyard one.

If it was up to me I'd weld a bolt/socket to it and take it off but I'm a little guy and I can barely get my arm in there to find the bolts so unless I'm completely missing something there's no room to modify the bolts in anyway

Angie · Aug 10, 2016

can you use something like these? works for me every time

http://www.canadiantire.ca/en/pdp/mastercraft-6-pc-bolt-out-damaged-bolt-nut-remover-set-0581208p.html

xA2D9 · Aug 10, 2016

Angie said:
can you use something like these? works for me every time

http://www.canadiantire.ca/en/pdp/mastercraft-6-pc-bolt-out-damaged-bolt-nut-remover-set-0581208p.html

That's what I was originally looking for but any one I find has 8mm and 10mm but neither work. 9mm would be perfect but just finding it a set with that. It has to exist just need to look more

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Teddlet · Aug 10, 2016

I think this is what you're after?

http://www.hfwilson.com/productDetail.asp?productNumber=66270&categoryId=4117

ratdude747 · Aug 11, 2016

You might be able to drill it and use a tap-style bolt extractor? Not a lot of meat there but not a lot to remove either.

adsm08 · Aug 11, 2016

I honestly think that most of you do not understand the lack of space to work in this area.

I have had the pleasure of doing these intakes on Focus and Fusion cars, and some of the bolts on this intake make me want to drag the idiot who designed the engine out into the street and go all American History X on him.

To the OP, do yourself a favor, and when you do finally get the intake off replace your PVC/oil separator, it's hose, and the thermostat. They are all under the intake.

Look into these sockets. Per piece the are not any worse than the HFWilson ones, but are more like a regular socket in design and tool attachment.

https://store.snapon.com/1-4-DRIVE-TOOLS-Blue-Point-174--C795638.aspx

pjtoledo · Aug 11, 2016

maybe try a 12 point socket or box wrench, something a little too small and pound it on? 12 pts are better at grabbing rounded stuff than 6 pts.

dremel tool with a cut-off wheel, try to grind new flats?

grip-it sockets, did you pound it on to seat it real good?

hit the head with a punch to mushroom it out a bit in hopes for a better grip?

hit it sideways to dislodge it?

hit it off center on the flange with a chisel to rotate it?

drill into the flange at an angle pointed at the center?

I doubt there is enough room, but a stud remover?

CRC freeze-off to shrink the bolt & crack the rust bond?

pound on a female Torx bit?

a socket with a bunch of pins inside that conform to any shape?

sacrifice the 9mm socket, pound on the end to reduce it to 8.5mm?

all long shots for sure, maybe you'll get lucky on one of them.

Perry

chewy012 · Aug 12, 2016

I've had pretty good luck with those extractor bits. Irvin makes a set that's like $30.

If you can't find the 9mm you need, try the American size that's close. They're sort of conical, so something as long as it's close should work. They'll dig in quite a bit.

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chewy012 · Aug 12, 2016

I'ma be doin my valve cover gaskets today too!

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xA2D9 · Aug 12, 2016

I managed to get the intake off, we grinded off the bolt heads through the wheel well and pulled (with lots of force) ended up taking 2 inserts out along with it. But now that I got that off there's plenty of corrosion on those 3 there's no way they would have spun how it was. But now I have room to move I got wd-40 sitting on it, heat, and vice grips for my first attempt if that fails weld some kind of head on it and keep trying, currently stuck with rain but hopefully some more progress will be made. I'll try to remember to grab a picture before I start removing so you guys can see what it is.

Thanks to everyone pitching in ideas for me!

Andy D · Aug 12, 2016

I would try driving a 3/8 socket onto them. If no joy, then maybe drilling them . If you snap an EZ out in the hole it becomes a real PITA.

Intake manifold removal problem

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