24 Valve 2nd Gen Dodge Cummins 98.5-02 Discussion of 24 Valve 5.9 Liter Dodge Cummins Diesels with VP44 Injection Pumps
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tap broke in manifold!

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Old Oct 15, 2010 | 07:42 PM
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Default tap broke in manifold!

ok so i have yet to pull a turbo...was hoping to do it when i got a new one but im afraid im going to have to pull it prematurely. i was tapping another hole for a pyro and the freakin tip of the tap broke off and now is inside of the manifold. what all will i need to make pulling either the manifold or the turbo..either one easier. tools,parts to take off first. any advise is great thanks guys
 
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Old Oct 15, 2010 | 07:52 PM
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Pull the turbo first. Probably will need a gasket for the oil return line, and another for the turbo to manifold. I have been able to reuse both before, but replacing is always best. At this point you have a choice, pull the manifold to be extra safe, or do your extraction and run the engine to clean it out. Not a bad idea at all. Remember, and this is my suggestion, the gas wrench (torch) can remove every bolt. Torch that SOB out, finish tapping the hole, run the engine to clear the debris out, and reassemble.
 
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Old Oct 15, 2010 | 08:00 PM
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what is best to use to get to the two bolts on the under side of the turbo flange...or to the manifold?
 
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Old Oct 15, 2010 | 08:03 PM
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I've always used a combo wrench. A 12 point socket would do the tick as well. A little heat on them wouldn't hurt either.
 
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Old Oct 15, 2010 | 08:07 PM
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yea as i found out by puttin some penatrant on the top nuts first...they were on there good now!!! is it bes to go from the bottom? i was looking when i started and there doesnt seem like a whole load of room in there. but it was also getting dark and i cant get all the way in the garage now
 
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Old Oct 15, 2010 | 08:16 PM
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Damn, sounds like your loosing your paddle up a certain creek. It is always best to apply the torque to the nut of a bolt set up. If not, turning one or the other will do the trick. If you have the room, give it a few good, hard, sharp hits with a hammer. Loosens things up.
 
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Old Oct 16, 2010 | 04:20 PM
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finished this morning...went well took about an hour to pull the turbo finish the tap and replace. thanks for the info
 
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Old Oct 16, 2010 | 04:43 PM
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Bad luck doesnt get much worse than that.
 
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Old Oct 16, 2010 | 07:35 PM
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Old Oct 16, 2010 | 07:48 PM
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Glad it worked out for you!
 
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