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Snapped a bolt. What do?


MSwezey

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Hey guys, first time posting here.

Spent the last weekend tearing my g/f's truck down to the heads and replacing all the gaskets as she was having a vacuum leak.

She also had an oil leak, which I was hoping it was a valve cover, but it wasn't.

Pulled the water pump and timing cover off. (Used extra RTV sealant on the bottom lip to seal it since I didn't want to deal with the oil pan since it wasn't leaking. Replaced those gaskets.

New thermostat and seal. New main seal. New water pump and fan equipment.
New plugs are in. With new wires on the way.

To the problem:

Like a dummy, I torqued the bottom bolts that go through the front of the oil pan into the timing cover to the same specs of the bolts going from the timing cover into the block. I snapped the of a bolt right off with not much effort in doing so. :badidea:

Picture: http://imgur.com/a/zc6S0

The very right bolt there circled in red.

Now as I said before I put RTV sealant down on that entire bottom lip.

Should I drill the bolt out? Or try to see if it develops a leak on me?

Remaining items:

Install new water pump.
Wait for fan, clutch, and pully to arrive from rockauto. Let's not talk about why.
Install radiator, fill, and bleed system.
I did the back brakes with new shoes and now the drums won't go back on. I'll have to play with the parking brake and see about fixing that.
 
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Doofy

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My credo
Shit Happens...Then You Die.
May or may not leak. If you are fond of your girl friend I'd just fix it right. I once twisted off 7 oil pan bolts on a HP 289. Just glad I still had the engine out. I have used a mini pair of vise grips and once a mini c-clamp. Both held up for years.
 

adsm08

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Get a left handed drill bit, a small one, and try to drill it out. The bit is likely to bite early on and just pull the broken out with it.
 

MSwezey

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Any clue what size/length that bolt is or where I can buy another?

Worst case I can try my luck at the local HW store and compare.
 

MSwezey

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So I was reading through some tutorials and how-tos on this truck & engine combo and I saw a detail that I never noticed before...

This truck has 3 different intake gaskets. Upper (between fuel fails and upper intake), middle (between fuel rails and lower intake), and finally the lower intake (between heads and lower intake).

I don't know how I missed this detail. Which makes sense now because the fel-pro valve cover gaskets came with the "upper" intake gasket which I thought it was weird because it wasn't the rubber O-ring type...Auto-zone even labels it as upper intake gasket. Am I the only one that thinks this should have been labeled more effectively?

Luckily putting that gasket where it belongs won't be hard as I've already tore the engine down further than the point needed. Just need to get the proper o-ring gaskets for the very top portion.

End rant.
 

adsm08

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It gets labeled as the "upper" because on the earlier 4.0s with the metal intake the upper and middle are the same. You just need two of them.
 

MSwezey

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I'm a little confused now with what you just said.

Everything I've seen is showing 3 levels of gaskets for the engine with the plastic plenum, upper, intake.

Here's the thread that's confusing me:

http://www.ford-trucks.com/forums/1032071-upper-intake-manifold-fuel-rail-gaskets.html

"Actually, you are correct; the pic linked in my previous post is the gasket between the lower intake and fuel supply manifold. " - Rockledge

Pictures:

http://www.ford-trucks.com/forums/232373-coolant-loss-4-0l-ohv-lower-intake-gasket-6.html

The set I bought thinking the intake gasket was a replacement for the rubber 0-Rings:

http://www.autozone.com/external-engine/valve-cover-gasket/felpro-valve-cover-gasket/67279_71308_2034/?checkfit=true
 

97RangerXLT

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