Sheared bolt... Oops!

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congo181

congo181

Well-Known Member
Posts
519
Location
Maidstone, Kent, U.K.
Sheared a bolt off while trying to remove the EGR pipe to fit a blanking plate.

Should I leave the other bolt alone now and hope for the best, or do I really need to have 2 bolts (and the blanking plate) in...

Trouble is, I reckon I've got to take the exhaust manifold off to allow me to drill out the sheared bolt - who knows how many more studs will break doing that :(

And yes, I did use penetrating spray before I tried to shift it :)
 
Well ive got the lower bolt in, and the blanking plate installed.
Trouble is, the EGR pipe has a flange that is designed to sit inside the Ex manifold. Now its sitting against the blanking plate so the lower bolt on its own wont pull the parts together squarely....

Hmmm....

Is it easier to remove the grill/fan/radiator or the exhaust manifold/turbo?
 
Well, managed to get a hole through the exhaust manifold flange - its not quite through the centre of the sheared bolt, but I've got an M5 cap head through it and now the plate and pipe is secured with 2 bolts!

Did the front Anti Roll Bar bushes too - what a difference! Now the front knocking has stopped, I can hear the back knocking :D

Oh well... onwards and upwards... :) Off for a test drive to see how my blanking plate works.
 
congo181 said:
Well, managed to get a hole through the exhaust manifold flange - its not quite through the centre of the sheared bolt, but I've got an M5 cap head through it and now the plate and pipe is secured with 2 bolts!

Did the front Anti Roll Bar bushes too - what a difference! Now the front knocking has stopped, I can hear the back knocking :D

Oh well... onwards and upwards... :) Off for a test drive to see how my blanking plate works.
Click to expand...

Well done! Good Job.

Enjoy all the extra miles per gallon!

CharlesY
 
I'll do the rear ARB bushes soon - such a simple and cheap job as you say cake-boy.

I can't find any others that seem to be as worn, but which are the ones I should definately be checking?
 
have a look at panhard rod bushes while your under there mate. suffered wandering stearing on mine since i got it, checked swivel preloads steering box etc but couldn't cure it. didn't find any noticeable play in panhard rod bushes but after checking everything else i decided to change them anyway. instant transformation and there only a few quid.
 
Thanks for the tip - I'll order the panhard bushes when I order the rear ARBs.

The Haynes manual says I need to disconnect the rear ACE to remove the rear ARB - do I need to do this if I'm just renewing the mounting bushes?

Also, it says I will need a hydraulic press for the panhard bushes - now the wife is using my hydraulic press to make cakes, so its unavailable - will I be able to press the new ones in with a vice?

Cheers
 
not totally clued up with disco 2 but i would imagine you can change bushes without removing arb completely, generally you only need a couple of inch movement to get to bushes. as for panhard rod i tried to push out with vice but wouldn't budge so i got blow torch on bush till the rubber caught fire the blew it out and quickly pushed centre of bush out. (careful not to get the extremely hot rubber on your hands it hurts like hell and is a bugger to get clean) you're then left with just the outer steel case of the bush in the rod. feed a hacksaw through the hole then carefully cut through bush casing but be careful not to cut to far or you'll damage panhard rod. when you've cut through use a hammer and chisel to curl the bush inward then it'll just tap out. I know this sounds a rough way of doing things but its better than paying extortionate garage prices not to mention if the garage didn't have a press they'd probably do it the same way.
 
DOH!!! obviously i'm not reading properly!!! YES you should be able to push bushes in with a decent vice just make sure they've got a smear of oil on them and there are no burrs in the panhard rod. Its a good idea to get someone to give you a hand holding everything steady to make sure bush goes in straight
 
Changed the rear Anti Roll bushes today - no more knocking from the rear! It's official - you can change them without disconnecting the ACE connections as My Haynes tells you to do.

Also changed the engine oil and both filters today - another job of the list.

Panhard next - now here's a good one - can I drive without the panhard rod on? Once I've removed it and the old bushes - I might have to take it somewhere to fit the new bushes if I fail at home - but can I drive with no pahhard bar?? Hmmm...

Any views?
 
congo181 said:
Changed the rear Anti Roll bushes today - no more knocking from the rear! It's official - you can change them without disconnecting the ACE connections as My Haynes tells you to do.

Also changed the engine oil and both filters today - another job of the list.

Panhard next - now here's a good one - can I drive without the panhard rod on? Once I've removed it and the old bushes - I might have to take it somewhere to fit the new bushes if I fail at home - but can I drive with no pahhard bar?? Hmmm...

Any views?
Click to expand...

you got a part number for the rear RB bushes?
 
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