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Car Engine Repair Hacks You Want to Avoid

There are a lot of car repair hacks recommended on the internet. Here are six for a common repair you should really reconsider before trying it out on your car’s engine.
When Car Hacks Are Not Repairs

Friday Automotive Humor While Learning Something Useful

Did you ever have one those friends that you just cannot help but like, but can only take in small doses? A good example is a recent Mike the Backyard Mechanic YouTube channel episode where the host applies some Junior High humor while actually teaching something useful on how to (or how not to) remove a broken engine stud.

Broken Engine Stud Repair Challenge
Removing a broken engine stud can be a challenging task; however, it is not always beyond the DIY mechanic given but the right tools, techniques, and most important of all―patience with a little luck served on the side.

Typical hacks for removing a broken rusty exhaust manifold stud or bolt include:

  • Penetrating oil (e.g., WD-40): Apply this to the broken stud and let it sit for some time to loosen rust and corrosion.
  • Heat source (e.g., propane torch): Heating the area around the stud can help expand the metal, making it easier to loosen.
  • Vise grips or locking pliers: Use these to grip the broken stud and attempt to turn it counterclockwise.
  • Left-hand drill bits: These bits are designed to turn counterclockwise, and sometimes they can catch onto the broken stud and help remove it.
  • Easy outs or screw extractors: These tools are designed to grip into the broken stud and allow you to turn it out.
  • Tapping tools (hammer and center punch): Gently tap around the broken stud to help break up any rust or corrosion.

Cons of These Hacks

The con of the majority of these hacks is the probability that you will wind up making a bad problem worse. Of the six listed above, only the application of penetrating oil and using heat to loosen a recalcitrant bolt are non-invasive…within reason. A small micro torch applied briefly to a broken bolt or stud will soften any brand of Loctite-like thread locker, but too much heat from too big of a torch can weaken a bolt significantly as well as damage the manifold or engine block.

The remaining hacks stand a good chance of causing additional damage that will need to be done to repair the repair attempt.

IMHO, the Easy-Out screw extractor type of hack is the worst because a broken screw extractor made of hardened steel stuck within a broken bolt or stud makes a repair significantly more difficult…and more costly to fix. Been there, done that.

Learning Stud Extraction with Humor

To learn more about the difficulties of removing a broken engine bolt or stud, here is a humorous take on the problem with common hacks recommended on the internet that should leave you with the wisdom of carefully rethinking what can happen when a hack goes wrong.

Related article: Ford Mechanic Catches Engine Rebuild Scam

Be forewarned, the host’s style of teaching can be a little annoying but is surprisingly useful as well as humorous.

5 ways to Remove a Stud Without a Welder

Best Recommendations for the Problem

If you are convinced that any of the hacks are ones you want to try, remember to take your time, work carefully, and use the appropriate safety precautions. If you're unsure or uncomfortable with any step, it's always a good idea to seek professional assistance.

If all else fails, consider seeking professional help, such as a mechanic or a machine shop that will possess the specialized tools and expertise to handle stubborn broken bolts and studs. More likely than not, you will find that paying for a professional to remove a broken bolt or stud can be less expensive than employing the aforementioned hacks.

Personal conversations with machinists have taught me that their biggest complaint is when DIY engine owners fail to stop after the first attempt or two and wound up creating a much more difficult (and expensive) repair than if they had come to the machinist in the first place.

One Last Caveat for Discouraging Attempting Engine Hacks

One consideration that typically does not come into play until after a DIY hack is used to successfully remove a stubborn bolt or stud is that of damage to the block threads. Drilling an oversized hole and inserting a Heli-Coil type insert requires exact drilling precision not suitable for most DIY home garages.

In other words, you may very well wind up having to go to a machinist anyway even though you were able to remove the bolt yourself.

For additional repair articles, here are a few for your consideration:

Timothy Boyer is an automotive reporter based in Cincinnati. Experienced with early car restorations, he regularly restores older vehicles with engine modifications for improved performance. Follow Tim on  “Zen and the Art of DIY Car Repair” website, the Zen Mechanic blog and on Twitter at @TimBoyerWrites  and Facebook for daily news and topics related to new and used cars and trucks.

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Image source: Deposit Photos

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