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How to Remove a seized and broken exhaust bolt from a turbo | Step-by-Step Repair Guide.

🚗 How to Remove a Seized and Broken Exhaust Bolt from a Turbo (DIY Guide)

If you’ve ever tried to remove an old turbo or work on your exhaust system, chances are you’ve run into a seized or broken bolt. It’s one of the most frustrating parts of working on turbocharged engines, and if done wrong, it can lead to expensive damage or hours of extra labor.

In this guide, I’ll show you how to safely and effectively remove a seized and broken exhaust bolt from a turbo, using basic tools and proven techniques that work even on the most stubborn bolts.

📺 Watch the full video here: 


(Step-by-step video walkthrough included!)





🔧 Common Causes of Seized and Broken Turbo Bolts



Exhaust bolts near the turbo are exposed to extreme heat, pressure, and corrosion, which can cause:


  • Thermal expansion and contraction (tightens the threads)
  • Rust and corrosion
  • Bolt fatigue and snapping during removal



Whether it breaks off flush or gets completely stuck in the housing, it’s important to stay calm and use the right tools.





🛠️ Tools You’ll Need



Before starting, gather these tools:


  • Penetrating oil (e.g., WD-40, PB Blaster)
  • Blowtorch or heat gun
  • Drill with cobalt drill bits
  • Bolt extractor (Easy Out)
  • Tap & die set
  • Safety gear (gloves, goggles)



🔄 Step-by-Step: Removing a Seized and Broken Turbo Bolt

1. Apply Penetrating Oil

Soak the bolt thoroughly with penetrating oil and let it sit for at least 15–30 minutes. If possible, apply it the day before for best results.

2. Heat the Area

Use a propane torch to heat the turbo housing around the bolt. The heat expands the metal and helps break the bond between the bolt and threads.

3. Drill a Pilot Hole

Using a cobalt drill bit, drill directly into the center of the broken bolt. Start small and gradually increase the bit size to avoid damaging the threads.

4. Use a Bolt Extractor

Insert an Easy Out into the drilled hole and twist slowly counter-clockwise. Apply steady pressure—don’t rush it. If the extractor bites, continue slowly until the bolt loosens.

5. Retap the Threads

Once the bolt is removed, clean the threads using a tap to restore them. If the threads are damaged, consider installing a thread insert (Helicoil).

🧰 Pro Tips


  • Always wear safety gear when drilling and applying heat.
  • Avoid using too much force—let the tools do the work.
  • If a bolt is too far gone, consider removing the part and taking it to a machine shop.


🎥 Watch the Process in Action

For a full walkthrough with visual guidance, check out my video:

[How to Remove a Seized and Broken Exhaust Bolt from a Turbo – YouTube](How to Remove a seized and broken exhaust bolt from a turbo | Step-by-Step Repair Guide.

https://youtu.be/dNGI95rDxxA)


💬 Final Thoughts


Removing a seized or broken turbo bolt can seem like a nightmare, but with the right tools, technique, and patience, it’s completely manageable—even for DIYers. Don’t rush, follow the steps carefully, and you’ll save yourself time, money, and frustration.


If you found this guide helpful, be sure to subscribe to my YouTube channel for more hands-on car repair tutorials, and drop a comment if you have questions or want to share your own experience!

#CarRepair #DIYMechanic #TurboFix #ExhaustBolt #SeizedBolt #TurbochargerRepair #AutoDIY #EngineRepairTips


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