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 Old 08-10-2017, 11:32 AM   #1
 
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Default Pulling stock K04, Veterans please advise

So where the exhaust manifold bolts to the turbos hot side housing with 4 bolts started to leak, I tracked it down with LTFT and STFT. 2 studs were backed out and it was about an 1/8 separated, pretty bad leak. Story short I snapped off a stud inside the turbo housing. What set of tools am I gonna need specifically for the stud back out, and what are some of the known, "while your in their might as well do this too" mods/fixes that should be done. Know any links for a k04-22 rebuild kit? Seals, gaskets? Lines replaced? Thanks guys.
ps: car is full bolt ons stage 3 gen pu

And please dear god don't say "BNR that shit and build the motor" lol

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 Old 08-10-2017, 11:40 AM   #2
 
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Find a machine shop that will take it out.

or, if there is some of the bolt sticking out you can grind flats on it so you can get a wrench on it or vise grips. If its still stuck drill a hole in it and use a easy out.

As for replacement stuff for sure the copper gasket between the turbo and the mani. I think edge auto also has replacement bolts and the gaskets.

P.S.

use PB blaster next time.
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 Old 08-10-2017, 12:46 PM   #3
 
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Man I know haha but I did I used PB blaster and used a dremel etcher to vibrate it loose (trade secret), and it still snapped while tightening. And I am a machine shop lol, I have a 1000 sq ft machine shop fully stocked. Every tool you can dream off. But what type of drill and back out and tap should be used. Any brands? Not new to engine building or effing exhaust bolts. Just not gonna pay someone and have access to most tools/gadgets
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 Old 08-10-2017, 01:34 PM   #4
 
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Just get a easy out set and drill a hole ON CENTER then use an easy out. Start out small and work your way up to a bigger size drill. The bigger the easy out the more torque on the bolt. The key is to stay on center so that you don't fuck the threads up. I would soak that shit in PB blaster until you get it out.

Do you have a Manual Mill? that would make it 10X easier. set it up on the mill and drill it out.
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 Old 08-10-2017, 01:42 PM   #5
 
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Of course I have a mill it wouldn't be a machine shop without one. If i remember correctly it was about $20,000 new so I trust it immensely. Ok yeah figured it would have to be a big hole, otherwise the easy out wouldn't have enough surface area far enough away from the rotational axis to apply enough torque to unstick it. Shweeeet

Then again a retard could use a 20k dollar mill and mess it up FUBAR but you get my point.

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 Old 08-12-2017, 03:26 PM   #6
 
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Please post pics when you mess it up. Thx.
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 Old 08-12-2017, 05:33 PM   #7
 
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You're a machine shop, but you don't know how to extract a bolt that snapped off?

Stage 3... lmao
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 Old 08-12-2017, 06:03 PM   #8
 
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[QUOTE=g00s3y;3125165]You're a machine shop, but you don't know how to extract a bolt that snapped off?

yeah..... I was skeptical too..
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 Old 08-13-2017, 12:01 AM   #9
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Originally Posted by Colepidd55 View Post
yeah..... I was skeptical too..
you're a good dude
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 Old 08-13-2017, 07:37 AM   #10
 
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How bad were your fuel trims with the 1/8 inch gap? I am trying to sort a possible leak myself. Found the drivers side bolts on the exhaust manifold to be a tiny bit loose - only an 1/8 of a turn to fully tighten though.
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 Old 08-13-2017, 09:37 AM   #11
 
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Yea you're not going to be able to use an easy out or anything like that on those studs. Think of how hot that gets and how many heat cycles it's been through. You're going to have to drill it out and tap, possibly add a helicoil. Ask me how I know.
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 Old 08-13-2017, 09:39 AM   #12
 
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@The_Boost_Buddha; "BNR that shit and build the motor" lol
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 Old 08-13-2017, 09:47 AM   #13
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Wait wait wait. You have a machine shop stocked with equipment but you're asking MSF on how to extract a stud???? I'm confused
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 Old 08-13-2017, 12:01 PM   #14
 
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Originally Posted by speed23 View Post
How bad were your fuel trims with the 1/8 inch gap? I am trying to sort a possible leak myself. Found the drivers side bolts on the exhaust manifold to be a tiny bit loose - only an 1/8 of a turn to fully tighten though.
STFT 25% and LTFT 10%

Originally Posted by g00s3y View Post
You're a machine shop, but you don't know how to extract a bolt that snapped off?

Stage 3... lmao
I'm a machine shop, was a funny response to another guy. I am not a machinist no, and haven't had experience working in a machine shop. I just have 24 hr access to a machine shop. Don't have to be a dick, no idea what you get out of going out of your way to be a fuck ass. Sorry god gave you a little dick

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 Old 08-13-2017, 12:47 PM   #15
 
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Originally Posted by The_Boost_Buddha View Post
Don't have to be a dick, no idea what you get out of going out of your way to be a fuck ass. Sorry god gave you a little dick
Oh my. You're definitely new around here.
@Djohns; - that's just a regular K04, right?
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 Old 08-13-2017, 02:59 PM   #16
 
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Originally Posted by zenit View Post
Oh my. You're definitely new around here.
@Djohns; - that's just a regular K04, right?
Yea just a regular ko4, that happened a little while ago.
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 Old 08-13-2017, 04:59 PM   #17
 
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Originally Posted by The_Boost_Buddha View Post
used a dremel etcher to vibrate it loose (trade secret)
Funny i thought shit like torching and kroil on exhaust bolts were trade secrets you must know what your doing.

Originally Posted by The_Boost_Buddha View Post
And I am a machine shop lol, I have a 1000 sq ft machine shop fully stocked.
Sounds like a pro to me.

Originally Posted by The_Boost_Buddha View Post
I am not a machinist no, and haven't had experience working in a machine shop. I just have 24 hr access to a machine shop
Sooooooooo why the fuck wouldnt you ask a machinist who works there to help you......

Originally Posted by The_Boost_Buddha View Post
Of course I have a mill it wouldn't be a machine shop without one. If i remember correctly it was about $20,000 new so I trust it immensely.
I would trust a epileptic teen with a strobe light drill after 5 beers with my turbo before i would trust you with a 20k machine. You sound like an ass hat throwing big words and numbers to look impressive since you cant figure out how to deal with a snapped stud. IMHO you shoulda just googled how to drill and tap broken stud since it is common and there isnt any exotic metals here....

You should just bnr that shit and build the motor.:
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 Old 08-13-2017, 08:59 PM   #18
 
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Originally Posted by 5doorsoffury View Post
Funny i thought shit like torching and kroil on exhaust bolts were trade secrets you must know what your doing.


Sounds like a pro to me.



Sooooooooo why the fuck wouldnt you ask a machinist who works there to help you......


I would trust a epileptic teen with a strobe light drill after 5 beers with my turbo before i would trust you with a 20k machine. You sound like an ass hat throwing big words and numbers to look impressive since you cant figure out how to deal with a snapped stud. IMHO you shoulda just googled how to drill and tap broken stud since it is common and there isnt any exotic metals here....

You should just bnr that shit and build the motor.:
How hot would said teen be and approximate age for legal purposes.
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Soon:built motor
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 Old 08-13-2017, 11:21 PM   #19
 
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Originally Posted by Djohns View Post
How hot would said teen be and approximate age for legal purposes.
Bahahahahahaha winning
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 Old 08-14-2017, 10:50 AM   #20
 
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Originally Posted by The_Boost_Buddha View Post
STFT 25% and LTFT 10%



I'm a machine shop, was a funny response to another guy. I am not a machinist no, and haven't had experience working in a machine shop. I just have 24 hr access to a machine shop. Don't have to be a dick, no idea what you get out of going out of your way to be a fuck ass. Sorry god gave you a little dick
Don't be sorry, your girl said it was the best she's ever had.

You don't know how to remove something from a hole. I wouldn't expect you to know how to put something in one correctly either.
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 Old 08-14-2017, 03:28 PM   #21
 
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Originally Posted by The_Boost_Buddha View Post
Bahahahahahaha winning
This is what I hear:
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 Old 08-15-2017, 05:07 AM   #22
 
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Originally Posted by g00s3y View Post
Don't be sorry, your girl said it was the best she's ever had.

You don't know how to remove something from a hole. I wouldn't expect you to know how to put something in one correctly either.
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 Old 08-15-2017, 02:12 PM   #23
 
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Originally Posted by 5doorsoffury View Post
Funny i thought shit like torching and kroil on exhaust bolts were trade secrets you must know what your doing.





Sounds like a pro to me.







Sooooooooo why the fuck wouldnt you ask a machinist who works there to help you......





I would trust a epileptic teen with a strobe light drill after 5 beers with my turbo before i would trust you with a 20k machine. You sound like an ass hat throwing big words and numbers to look impressive since you cant figure out how to deal with a snapped stud. IMHO you shoulda just googled how to drill and tap broken stud since it is common and there isnt any exotic metals here....



You should just bnr that shit and build the motor.:



Holy fuck! "I would trust an epileptic teen with a strobe light drill after 5 beers...", you sir are my hero today


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 Old 08-15-2017, 06:17 PM   #24
 
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You guys rock! Anyway back to the reason this thread was started, are there any, "while you're in the might as well" mods or replacements I should do, and are there any NON EBAY, NON CHINESE k04-22 rebuild kits available to us
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 Old 08-15-2017, 09:23 PM   #25
 
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The K04 is not serviceable. Buy a new one or upgrade to an ATP bolt on.
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 Old 08-16-2017, 04:55 AM   #26
 
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Buy a BNR and build that motor.
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 Old 08-16-2017, 09:45 AM   #27
 
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Originally Posted by Reedy View Post
The K04 is not serviceable. Buy a new one or upgrade to an ATP bolt on.
Wow, that's amazing. How was I able to rebuild mine, when I was still k04, if that's the case?
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 Old 08-16-2017, 02:13 PM   #28
 
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Probably by wasting your money. What parts did you actually replace? The advice I've been given is its not designed to be serviceable. Maybe that was a translation for not worth doing.

Edit: You're right, but the kits are out of spec right out of the box so in some cases it's abit of a lottery. (Just checked to make sure, that's the reason why my guy won't do them)

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 Old 08-16-2017, 02:56 PM   #29
 
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Originally Posted by g00s3y View Post
Wow, that's amazing. How was I able to rebuild mine, when I was still k04, if that's the case?
Did you use a kit from eBay or otherwise?
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 Old 08-16-2017, 05:04 PM   #30
 
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In order of priority, please:

#1 - search noob

#2 - suck it
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 Old 08-16-2017, 05:37 PM   #31
 
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Ive been using a rebuilt ebay parts ko4 for 60k miles. Going strong still.

Edit: This is the guy I bought mine from - apparently sold 20 and no issues with ebay kit. Somewhere in his posts I recall him saying exactly which kit he used:

http://www.mazdaspeedforums.org/foru...lt-k04-191182/

That said, the PITA it is to switch on the 6, I would just go BNR stage 3.

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 Old 08-17-2017, 05:48 AM   #32
 
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Originally Posted by Reedy View Post
Probably by wasting your money. What parts did you actually replace? The advice I've been given is its not designed to be serviceable. Maybe that was a translation for not worth doing.

Edit: You're right, but the kits are out of spec right out of the box so in some cases it's abit of a lottery. (Just checked to make sure, that's the reason why my guy won't do them)
its a lottery because its ebay. If you buy the kit from a respectable turbo service shop you'll be just fine. Keep in mind there are several versions of the K04(think vw). Its EASIER to just buy a bnr/cs, that doesn't mean that the K04 doesn't have potential. The problem is/was that people wanted silly money to modify the K04 that approached the prices of just getting a bnr/cs upgrade. There are several issues/limitations with the stock unit, but that doesnt automatically mean its garbage. Got an extra $1200 to spend on an upgrade have at it, but you can make plenty of power on the stocker.
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 Old 08-17-2017, 07:37 AM   #33
 
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Originally Posted by Reedy View Post
Probably by wasting your money. What parts did you actually replace? The advice I've been given is its not designed to be serviceable. Maybe that was a translation for not worth doing.

Edit: You're right, but the kits are out of spec right out of the box so in some cases it's abit of a lottery. (Just checked to make sure, that's the reason why my guy won't do them)
It was before I started having everything automatically backed up by google photos, so this is the only photo I have of it. Everything worked perfectly fine after, no loss of any kind, no problems of any kind.



People really need to chill with all the ebay hate. It's no longer the clusterfuck it was 10+ years ago with 75% of the products being garbage. Its basically the site to get shit from china for cheap, since it's the same place a "name brand rebuild kid" is coming from also.
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