6.7 Powerstroke broken EGR bolt SOLUTION!

[@DeapJaz]

Thanks for this excellent video. Impressive tool! Truck's at the dealership now. $800 if the bolts comes out. $4,000 to replace the exhaust manifold. Expansion bellows failed on right egr pipe. Happened while pulling 16k towards Monarch Pass. Since I'm not at home I looked for a Dealership. Was fortunate that it happened before leaving Salida, CO, not 2 miles from dealer. I'll be forwarding this info to the mechanic for future consideration. I want to get moving ASAP and not ready to be the trial customer. Again. Appreciate this well done video.

[@casval-pj5tb]

I've had my top end taken apart multiple times, if you're gonna do that you should also buy the BD manifolds. The drivers side manifolds on these trucks warp and leak, makes a screeching sound as the exhaust gasses piss out. You don't need to pull the cab to get the turbo out, but its tight and the turbo has to be turned to about 10oclock to come out. If you dont have the time or tools which all you really need are 10mm 8mm, 1 7mm if I remember correctly and the proper extensions. Hardest thing are the vband clamps on the cobra pipes. Its not a 4k job. If that's the case my truck has 90k in repairs, I've done everything myself.

[@wheelinndealin]

Dude you are awesome at making videos, perfect, thorough explanation. Thumbs up👍🏻

[@InTheShop]

I appreciate that! Thanks for watching!!

[@duconce]

For do it yourself , it's an expensive problem. 500 for the kit, thanks for the videos. I like the option you point out like on the EGR

[@adammiller8415]

Even for a mechanic its expensive. The inserts are priced stupid expensive. Unfortunately your stuck with the insert they make. Its ridiculously over priced

[@brooster87]

Great job. Thank you so much. I had to pull my egr but thankfully no bolts broke. Now I know I can fix it if it does. Awesome quality and great instructions. Thank you.

[@rafaelmarin1963]

Thanks for the info. I'm not a mechanic but I love wrenching on cars. Kind of pricey but then again so are pro shop rates. Thanks for the video, you're doing it right.

[@InTheShop]

Thanks for watching Rafael.

[@TheLPayne]

Hey my friendo will you please move to Junction City Oregon and help out us Ford Truck owners. We need someone that knows his way around a 6.7 diesel and you are about the best I've seen!!!

[@darrellparsons246]

Thanks so much, super cool jig system with great instructions.

[@InTheShop]

It’s a little pricey but definitely worth it.

[@samsgarage1716]

Nice kit.Im always stuck doing it the old fashion way.👍

[@InTheShop]

It's really well put together.

[@Augiebracerofam]

Well done. Thanks for the links, including your silicone ring.

[@InTheShop]

Thank you! I’ve been wearing their rings for a couple years now. Wicked comfortable especially at work.

[@kendallarian3887]

you prolly dont give a shit but if you guys are stoned like me atm then you can watch pretty much all of the latest series on InstaFlixxer. Have been binge watching with my gf for the last few days :)

[@royalhamza3579]

@Kendall Arian Yup, have been using instaflixxer for years myself :D

[@jbyrd4559]

Just did this it is nice but the bits do wear out quickly. For 500 they need to include more bits. A 9 mil socket works to fit over the end of the tap. They use black oxide inserts now and you need to buy red locktight to finish it up. They don't include that either.

[@davidbradford5432]

Easy, don't loosen the bolts, then they won't break. And yes I have done egr replacement with bolts tight. I will look into getting this kit. Also always use new bolts!! Get them from ford.

[@appliancerepairshorts]

Man awesome tool, but I think they should have made the drill bits to drill in reverse then tread it in reverse and remove it, but I understand this kit is fixing the original problem

[@InTheShop]

Unfortunately reverse drill bits wouldn't get them out. The bolts fuse themselves into the threads and wont spin out. Reverse drill bits are awesome just not for this application.

[@OUTLAWBBQ]

They always break on me. I have good luck with a bottom feeder burr. It's still a 4 to 8 job, though. It really sucks when one of your drill bits breaks off in the bolt.

[@leviross9450]

Weld a nut to it. Just did it to mine and it worked flawlessly

[@InTheShop]

That’s the technique I typically use for broken bolts and works great in most applications. You got lucky it worked for you for these bolts. The issue is if they gall the threads the bolt will just keep snapping below the weld. Then because of the heat applied from the weld the bolt becomes almost impossible to drill.

[@leviross9450]

@@InTheShop I did it before I snapped it off. I could tell it wasent going to budge. I didn’t even need a ratchet. Just an extension and spun it out with my fingers. Try it out. It might work good for you too

[@mlvcustomsllc5395]

Bolts look dry as if never PB blasted or hit with a penetration oil! Also not one video here shows anyone heating the bolt up with a torch prior to attempting loosening it. Curious if my snap on reverse drill bits would help at all. I'm doin a full delete next weekend on my f350 so wish me luck!

[@InTheShop]

michael velez I have another video about doing EGR coolers showing heating the bolt and getting them out. This solution is for the unfortunate circumstances where the bolt ends up breaking. Thank you for watching!

[@InTheShop]

And there is no PB on this one because i purposely broke the bolt to demonstrate the tool.

[@mlvcustomsllc5395]

Ok, I understand that. I'm gonna shoot mine everyday till Saturday when I begin my delete process. I'm using WD specialist. Seems to work a faster and doesn't stink like PB blaster! I'm spraying all the dpf pipe bolts and everything on the egr.

[@nabielsuleiman7039]

High ended up blowing my PCM and harness was bad also and all I did was bump my HNS tuner, which came unplugged, and it shorted out my PCM and harnessed who would’ve guessed cleaning off the dash and bumping the HNS programmer, would delete my PCM and blow fuses couldn’t find no short no ground but couldn’t get signal through harnessed. Either ended up replacing PCM harnessed reprogramming PCM a very costly mistake I guess or mishap to a tuneup $3000. Have you ever heard of anything like that?

[@brianwayne3029]

Excellent video! Thank you!

[@ggrebenyuk]

Can you just drill new holes next to the broken bolts? Would be much easier.

[@robdelisle4502]

Please tell me why they dont just use inserts when making manifolds! Id op for that over leather seats, and a damn moonroof.

[@InTheShop]

Cost. Most people just want the truck to be pretty and comfortable. They always complain down the road though when the repairs start adding up.

[@philliplawson2001]

I hear the trick to these is just grind the head of the bolts off. and remove the pipe, then use heat and a pair of vise grips to get them out, WAY less hassle.

[@InTheShop]

Might be a little tough to get a grinder on them. I usually heat them with a small brazing tip on my oxy torch then slowly work them out but if they do break this is the best route.

[@aarongodderidge2239]

So let me ask you this. Is it worth drilling and tapping these even if they don't break off? Like you said the EGR is going to come off more than once so i was thinking about doing this the first time regardless of weather or not it breaks that way i don't have to try and do it with a broken bolt in it....

[@InTheShop]

I think it would be a great idea if you plan to have the truck long enough to have to go back in again. The kit is not cheap but will save you a ton of headaches.

[@johnthemechanic2937]

Good instructions, where did you order the replacement bolt?

[@InTheShop]

Thank you! Right from ford.

[@Nostradamus_Order33]

Thanks for the video

[@InTheShop]

Thank you!

[@dolores302]

Just use it today. Waste of 500 bucks. The plate doesn’t stay in place and buys burn up fast

[@jasongruber5524]

awesome job

[@InTheShop]

Thank you!

[@AaaaandYerDhem]

Great video man. Thanks

[@alberth8073]

Not a fan of drilling. It's right on top and fairly easy to reach. Put a rag in the hole to protect from splatter and weld on a nut with wire welder. Make sure to disconnect the battery neg and put ground close.

[@InTheShop]

Welding a nut to broken bolts is typically how I remove them. That being said have you ever tried to remove these particular bolts that way? The reason they break is because they basically weld themselves to the manifold. I found it faster and easier with this method. I have en entire video about welding nuts to broken bolts.

[@956rudy7]

If a peace of the bolt fall in the manifold hole will that cause any problems?

[@InTheShop]

I would definitely get it out before running the truck.

[@codyhenry3926]

They've had a kid around just like this for Harley. Davidson heads for quite some time.. But instead of trying to rob people 44 hundred and some dollars. The most expensive one I could find is just under two hundred bucks.. I think I picked a Jim's brand one For eighty bucks... I just can't justify their price for this tool.. For what it is

[@jayl314]

Nice job.

[@InTheShop]

Thank you!

[@R2RMINISTRIES]

I broke all 3 starter bits that came with this kit! WTF!

[@AaaaandYerDhem]

There's an art to drilling. Push down too hard or go in crooked... Things break. Straight on and easy does it

[@antn8387]

ugh I hate how ford moved away from variable band clamps..

[@juanguillenmunoz3187]

Where can I get that tool to remove the broken bolts

[@toxicpurple7453]

Jb tools

[@Seabass466]

How much is the kit? I read somewhere $499 I sure hope thats wrong

[@InTheShop]

The kit has a few options and add-ons and ProMaxx usually recommends calling them for the best value. That being said the amount of time it can save is worth it’s weight in gold. Especially if you work on these trucks often.

[@russellaustin4988]

Do them all the time. Never have to drill them. Cut the head off and take them out with pliers.

[@anthonymcdaniel592]

Use r bit tap to 1/8 not 27 in a plate use 1 3/8 hole saw retieve coupon weld it up with cast iron rod and be done with it

[@InTheShop]

Not an option in a lot of states that require an emissions test.

[@anthonymcdaniel592]

@@InTheShop how so when the sensor is installed

[@InTheShop]

@@anthonymcdaniel592 egr insufficient flow code. If you don’t tune it and if you do tune it the EGR monitors will say “not ready” and in a lot of states that plug in for testing a not ready on egr is a fail.

[@ryanbergschneider]

can I borrow yours? $500.00 is just too much to pay for that dang tool.

[@InTheShop]

It is expensive but can save you a lot of time and money. Unfortunately i don't loan out my tools.

[@danikael2815]

500 dollars for that tool a replacement manifold is about 170 my guy thats too much for that simple of a task thats insanely expensive

[@InTheShop]

That all depends on how much you value your time. Pulling the turbo and dealing with the manifold is a decent size job. Also most people that buy this tool either use it then sell it to recoup some of their money and save the next guy some cash or they work on these trucks regularly and will be doing this repair on more than one truck.

[@danikael2815]

@@InTheShop even so theres centering tools with the whole nine yards from 20 to 80 bucks with the bits extracting tools and centering tool i mean if you have affiliation with them i get it but as a big influencer how can u justify that 500 to remove a bolt and thats before taxes i love your content and don't get me wrong its just that thats waaayyyy out there for what it is i watch a lot of your videos but thats just insane and yes the resale value holds but common man the community of powerstroke owners needs better than this man

[@InTheShop]

@@danikael2815 my only affiliation is they sent me the tool. They told me to use it and review it either positive or negative. 90% of the time you can not extract these bolts because they are galled in and will not extract. Drilling them without the jig can be very difficult since the bolts are titanium alloy and the manifold is much softer. The tool is expensive and I told them that. Can the job be done without this? Yup but this makes it fast, easy, and accurate. If you plan to fix this problem once then throw the tool in the bottom drawer of your toolbox forever I would say it’s likely a bad investment.

[@Meatmarket2002]

Delete it, simple long term fix. Break the bolt buy this as a delete plug and move on.

[@InTheShop]

Unfortunately not everyone has that option. More and more states are cracking down on deletes.

[@BigFrogs4x4]

Even glowing red both of my bolts broke off

[@InTheShop]

Yeah it happens sometimes. Did you try this kit?

[@BigFrogs4x4]

@@InTheShop my boss doesn't want to spend the money for it. We don't normally work on diesel trucks. It was just a really good customer of ours that has other cars we work on and he didn't want to turn down the job.

[@BigFrogs4x4]

@@InTheShop so my boss was drilling them out and just snapped a bit off down in the hole. How hard is it to replace the exhaust manifold? Lol i tried to get him to buy the tool. :-)

[@Austin2276]

@@BigFrogs4x4 what did you guys end up doing

[@BigFrogs4x4]

@@Austin2276 drilled out and tapped to the next size up.

[@armandomaldonado1559]

It's just not so productive.How come they didn't put 2 bolts?And you have a nut on top and tighten it down.How stupid are the engineers

[@DarinWheeler1967]

Great video but it doesn’t do me or anyone else any good if we don’t know how much it is. 😉

[@InTheShop]

The kit goes for around $499 depending on the options. Promaxx doesn’t list a price on their site. There are a few options that change the price up or down and ProMAXX occasionally runs deals.

[@DarinWheeler1967]

I appreciate the response, didn’t mean to sound like a jerk. Once again, great video and great product. 👍🏻

[@InTheShop]

No problem. You didn’t sound like a jerk. It was a great question. Thanks for watching!

[@umpman04]

Do yourself a real favor dude. Vacuum those metal shavings out of there. Save yourself ALOT of headaches. Like hospital trips for you ! ! Whata' you thinkin' ? ? ? ? ? Awesome tool though..................Thanks

[@christownsend7602]

Cool looking tool but, $500. Are you kidding me?

[@InTheShop]

I would say it’s best suited for someone that will likely do this kind of repair more than once. Another option is to use it once then sell it to someone else that needs it. It’s definitely not the cheapest solution but it’s the easiest.

[@christownsend7602]

I may have over reacted with my view of the price of the bolt extraction kit. I do think it may be more expensive than it could be but, it does appear to be a well made kit. As a millwright and machinist for over 40 years I have drilled out more bolts than I can remember. Stainless steel, titanium and Allen bolts, plus just the regular steel, so I can appreciate anything that makes that an easier job.

[@chupamandante1]

Hi I have a question, how much cost that job ?

[@InTheShop]

Repairing the broken bolt or the EGR cooler replacement.

[@chupamandante1]

@@InTheShop the two jobs