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cambox removal prob

smiffyraf1

smiffyraf1

New member
hi guys feel like im spending most of my life on here asking for advice now :)
started taking the cambox this weekend as the gasket has been leaking quite bad and thought id do the belts at the same time and found all of the bolts rediculously tight even with a breaker bar was a struggle and on one of the bolts under a plug at the top of the box the allen drive snapped in the head pretty much flush with the bolt. am pretty much stumped how to get this bolt out now, thought about hammering a socket down over it but because the plug hole is pretty small after grinding a 12mm down to get through am pretty sure it would crack when hammered. also thought about drilling allen bit out and if still not budging drilling the head of the bolt. and then thought as its the access thing thats a pain to just smash the cambox with a hammer and remove the bolt with loads of access and get a new box.
any thoughts or advice greatly appreciated
james
 
Are you saying the allen bit broke and not the bolt head?? and it is stuck in the bolt? I would weld a nut or bolt to the top of the allen bolt/head and undo it that way.
 
yeah the allen snapped off in the head of the bolt, again that would have been an option if there was good access think its about a 15mm hole you go through to get to the problem bolt
 
James, see if you can get a jewelers screw driver down the side of the broken bit to wiggle it out, if not you may have to trash the cam box to get into it as the Allen bit will be hardened and will not drill out. The bolts on these are a right pain, I have had to drill out plenty before! If you have to trash it, I have some good cam boxs here if you need a spare. If any of the Allen bit is proud, you may be able to grab the tip with some needle nose pliers, the broken bit will probably be pretty tight though. If you smash, the side, use a large chisel and try not to get small slivers of alloy into the return oil ways, see if you can punch a clean hole, I have had to do this once myself and get the remnants of the bolt out with a set of mole grips and heat. A good tip before you try to get the bolts out is to give the socket a good hit with a hammer to shock the bolt slightly to loosen the thread. Also use a good quality socket too like Snap On or SP or similar, no monkey metal as you will be asking for lots of rounded bolt heads!
Alasdair
 
yeah have tried getting the little bugger out its jammed solid and its snapped just below flush, ive never seen anything like it!! it was a pretty good quality bit as well. yeah i was worried about getting swarf and chunks of metal lost thats why i wasnt keen on drilling it. ive always hated allen bolts, a normal bolt just makes more sense to me. thanks for the advice and the box offer. how much do you have them for?
 
Hi James, is it a normal 2.5 N/A engine? A cover plus courier delivery would be £40 including bolts.
Alasdair

 
I ALWAYS use Irwin extractors on allen/torx type bolts if they dont crack off under normal pressure. To strip them internally etc is such a pain.

They generally dont damage the outside and you can the reuse them with an allen/torx key etc

418Kz06JJwL._SL500_AA280_.jpg


They are a life saver on old rusty bolts/nuts and dont wear out or break.
 
ORIGINAL: smiffyraf1
...on one of the bolts under a plug at the top of the box the allen drive snapped in the head pretty much flush with the bolt.
Click to expand...

I had the same problem many years ago. An imperial socket was used over the top of the Allen bolt to remove it. Using the type suggested by Hilux is better still as they look like they won't slip when they start turning.

You should be able to remove your current cambox without damage.

Regards,
Andrew
 
its the access thing stopping me doing something like this already. think the plug hole is about 15mm. you can get a 11mm socket in there, just. but thats far to small to hammer on to the bolt.
 
I recommend you take professional advice on this one. I had exactly the same problem and it was resolved as stated. If you try and do anything else, you run the risk of creating other problems.

If you are really stuck, send me an email (asweetenham@uku.co.uk) and I'll put you in touch with someone that can help.

Regards,
Andrew
 
I second the use of Irwin bolt extractors- best £18 I ever spent on tools. So good I bought the other part of the set.

These are also great for getting the bolts out of S2/Turbo brake calipers to deal with plate lift.

Another suggestion- drill off the top of the bolt with the remains of the Allen bit inside. If all the other bolts have undone OK. BTW, can you post a picture? I am unsure as to exactly where the problem bolt is, and am just giving general "how to deal with sheared bolts advice".

A Picture or three would be good.
 
Yeah again them extractors do seem good might get some anyway for the future. There's just no way I'd get them through the plughole on top of the cambox to get on the bolt. will get some pics when I can but basically the plugs are above the 'porsche' writing on the cambox and beneath each plug about 2.5" down are the Allen bolts and with the plug hole being about 15mm diameter it's a struggle to get anything near it. Thanks for all the advice though.
 
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