broken tap removal

[bmxr4life87]

well the inevitable happened today. While tapping out a hole in a less than favorable position the tap broke off. Now the tap is a good 1/4" below the surface and its a pretty small tap. The tap is a m5 x .8 it is for the ignition coil hold down bolt on a 99 f350 super duty with the 6.8 v10. It was on the #9 cylinder so its under the cowl and doesnt have a lot of overhead room to work. Ive got a wilton tap extractor but it wont get a good enough bite on the flutes to do any damage. The tap was a matco and its in an aluminum intake but its a through hole so the tap is through the bottom of the hole but i have almost zero access to the bottom to grab it in any way.... Please offer me any advice you have!

 

[-B-]

I have broken off m5 taps in frames, I usually end up shattering them out with a automatic center punch.
I use HSS taps and useing them in CroMo eventually they will break, it is even worse when the m2 breaks

 

[Fedwrench]

Walton broken tap extractor set.
http://www.toolsource.com/11pc-extractor-p-50740.html

You might be able to gently walk the tap out by tapping on it with a pick or small punch.

 

[bmwpower]

Ugh....pull the intake?

 

[Kevin54]

Tap extractors very rarely work so you might as well forget that. I can get them out at work but that is using a carbide endmil or drill to get them out. If the tap is sticking through the hole you may be able to punch it on through and only loose the end of your threads. You also may be able to drive it on through and them maybe helicoil it.

 

[bmwpower]

Tap extractors very rarely work so you might as well forget that. I can get them out at work but that is using a carbide endmil or drill to get them out. If the tap is sticking through the hole you may be able to punch it on through and only loose the end of your threads. You also may be able to drive it on through and them maybe helicoil it.

Yea, but it sounds like access is nil. Not sure you can get a good, square swing on it.

 

[bmxr4life87]

yeah pulling the intake is a pretty decent undertaking its a damn v10. Theres not enough room to drive it clean through and the hole is so small im going at it blind as i have to lay across the grill to even reach the hole and the tap is so far down in it that a punch wouldnt work. the threads can be upsized no problem i just need to get the old tap out i believe its all in one piece (not fragmented) and as previously mentioned im not having good luck with the tap extractor it wont bite good enough

 

[bmwpower]

I don't supposed drilling out a tap is even possible especially with limited access, eh? Can you get a small air drill in there?

 

[Speed-Racer]

Try some PB blaster and maybe a little heat, if you can get the tap extractor to work.
http://www.waltontools.com/products/extractr.htm

For the amount of time required to try to get the broken tap out, it may be easier and quicker to pull the intake. Wish I had better advise to offer.

 

[Plombob]

PB blaster? What the heck is that?

 

[Speed-Racer]

http://www.pbblaster.com/

http://blasterchemical.com/display.cfm?p=50003&pid=4

 

[Vicegrip]

Can you Mig weld something to it?

 

[toadjammer]

If you are able to get a dremel/pencil grinder in there you can use a carbide burr to chew away the tap. I am talking about 1/8" diameter burs.

 

[goodfellow]

Got a welder? Carefully build the broken tap up flush with Mig wire or welding rod, then take a flat washer and put it over the hole, and weld the washer to the built up tap material. Now take a good sized nut and spot weld it to washer.

Next, use an appropriately sized wrench on the nut and slowly try to unscrew the tap. Between the heat from the welding and the torque from the nut, you stand a good chance of getting the broken extractor in one operation.

It sounds like a lot of work, but it can be done very quickly --

Good luck!!

EDIT -- you will have to pull that manifold if you have zero clearance to work with -- regardless of what method you choose

 

[isr2kba]

Got a welder? Carefully build the broken tap up flush with Mig wire or welding rod, then take a flat washer and put it over the hole, and weld the washer to the built up tap material. Now take a good sized nut and spot weld it to washer.

Next, use an appropriately sized wrench on the nut and slowly try to unscrew the tap. Between the heat from the welding and the torque from the nut, you stand a good chance of getting the broken extractor in one operation.

It sounds like a lot of work, but it can be done very quickly --

Good luck!!

EDIT -- you will have to pull that manifold if you have zero clearance to work with -- regardless of what method you choose

I'll remember that idea. I can count on one hand the number of times I've broken off a tap before, but each occurrence is memorable in its own nasty little way.

 

[krusty the clown]

left handed drill bit? pulling the intake really isn't that bad a job either.

i wouldn't recommend it but i have seen shock bushings wedged between the coil and fuel rail to hold the coils down.

 

[Keep]

If it is not really really stuck in there, you can take a couple small brad nails, put them on each side and use a flathead screw driver to pull it.

I have had luck with this a couple times. Other times it took a lot more work.