Valve cover internal screws broke off....Is this valve cover done for?

[Levy3Poop]

Photo of the broken screws: http://i.imgur.com/rQAx3AZ.jpg

I JUST got this valve cover back from powder coating today, and I was going to put it in, but when I went to reinstall the black plastic piece on the inside of the valve cover, I had 2 screws break on me. I can't get them out with a Grabit I got from lowes. Is there any specific type of professional I could take it to to have the screws removed? parts.bmwofsouthatlanta.com doesn't even list the internal plastic part for the valve cover or the size screws it takes.
Do you think these broken pieces would wiggle their way out? I mean, they're tiny screws that don't take much torque at all to stay in.
I'm pretty bummed because I just paid $75 to have the valve cover powdercoated, and now this happens and makes me think I should cut my losses before a broken bit of screw drops into the engine and destroys it.

[jaredmac11]

I accidently snapped a reverse thread bolt when doing my M54 vanos. Wasnt being careful and it broke in half.

I got a very small drill bit and started a hole. Then I got a drill bit that was larger, but definitely smaller than the broken screw. The larger drill bit was able to 'bite' in to the hole the small drill bit made and I succesfully extracted the screw.

Since this is not a reverse thread bolt (I assume?), you are going to need a counter sink drill bit. Use a lot of PB plaster/silicone spray. Leave it overnight. The next day/morning, use the counter sink drill bits to extract the bolt.

I am not familiar with the bolt on the plastic panel but is there a chance a hardware store would have them?

[Levy3Poop]

I accidently snapped a counter-sink screw when doing my M54 vanos. Wasnt being careful and it broke in half.

I got a very small drill bit and started a hole. Then I got a drill bit that was larger, but definitely smaller than the broken screw. The larger drill bit was able to 'bite' in to the hole the small drill bit made and I succesfully extracted the screw.

Since this is not a counter sink screw (I assume?), you are going to need a counter sink drill bit. Use a lot of PB plaster/silicone spray. Leave it overnight. The next day/morning, use the counter sink drill bits to extract the screws.

I am not familiar with the screws on the plastic panel but is there a chance a hardware store would have them?

Thanks so much for all the advice. So you start with a small drill bit, and work to one that's JUST shy of the width of the screw? I'm not sure what a counter sink drill bit is, so you lost me there. How do you get the loose metal flakes out of the hole? I'd really like to avoid any loose metal in my engine lol.

But man, seriously...the plastic piece and screws on the inside of the valve cover are like a ghost. They're nowhere on the bmwofsouthatlanta catalog. They're pretty small, maybe 4mm on the threaded part.

Here's a picture. Sorry it's so unclear, I had to use my goofy little fish eye attachment to get a close enough pic with my phone

http://i.imgur.com/arEonhq.jpg

The socket part is 7 or 8mm, and the head looks like it says "KX 8.8", but it's so small that's just a guess

[jaredmac11]

Crap man, thats definitely a specialty bolt.

And I used the wrong terminology, I'll update my original post. It's not counter sink but a reverse thread or left-handed drill bit. Regular drill bits bite in at a clockwise pattern. Reverse thread goes counter clockwise.
Basically this means when the drill bit gets a 'bite' on the broken bolt, it will start to back out the bolt as the drill bit digs in deeper in to the bolt.

This is why you have to use PB Blaster or silicone spray though. You want the bolt nice and lubed up so it will begin to back out of the threads while the drill bit is biting in to the bolt, otherwise you'll just dig in to the bolt without a successful extraction. The torque of the reverse thread drillbit SHOULD be enough to back out that bolt, but the PB blaster helps.

Just be very very careful and aim straight down so you dont go through the bolt and in to the threads and muck the whole thing up. I just used a smaller drill bit first because I wanted to make sure I got a good starting point and was right dead center of the broken bolt. Then I went just a bit bigger from the previous drill bit while making sure it was smaller than the diameter of the broken bolt.

Here's a picture to get an idea:

http://imgur.com/MRMLYy2

If the part doesnt exist in OEM you PROBABLY cant get it.. An option would be to buy a junkyard valve cover if its cheap and use those bolts? Or just get it redone.

Sorry man.

[jaredmac11]

I tell you what,

I have an extra E30 valve cover.

Let me try and get those bolts out if you can successfully extract them.


Just pay for shipping and they are yours. Try and extract em first tho, I dont really wanna send em off if you cant get the broken bolt out first.

[Levy3Poop]

Crap man, thats definitely a specialty bolt.

And I used the wrong terminology, I'll update my original post. It's not counter sink but a reverse thread or left-handed drill bit. Regular drill bits bite in at a clockwise pattern. Reverse thread goes counter clockwise.
Basically this means when the drill bit gets a 'bite' on the broken bolt, it will start to back out the bolt as the drill bit digs in deeper in to the bolt.

This is why you have to use PB Blaster or silicone spray though. You want the bolt nice and lubed up so it will begin to back out of the threads while the drill bit is biting in to the bolt, otherwise you'll just dig in to the bolt without a successful extraction. The torque of the reverse thread drillbit SHOULD be enough to back out that bolt, but the PB blaster helps.

Just be very very careful and aim straight down so you dont go through the bolt and in to the threads and muck the whole thing up. I just used a smaller drill bit first because I wanted to make sure I got a good starting point and was right dead center of the broken bolt. Then I went just a bit bigger from the previous drill bit while making sure it was smaller than the diameter of the broken bolt.

Here's a picture to get an idea:

http://imgur.com/MRMLYy2

If the part doesnt exist in OEM you PROBABLY cant get it.. An option would be to buy a junkyard valve cover if its cheap and use those bolts? Or just get it redone.

Sorry man.

Thanks for your advice. I'll try and find a reverse drill bit, but it'll be tomorrow before I can go to Lowe's or anywhere. Do you think any sort of liquid lubrican would work, like bike chain lube?

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[jaredmac11]

Not sure. I always have liquid wrench handy but I havent used the chain lube before.

I would use a small, small drill bit (dont press down too hard, let the drill bit do the work) then use another drill bit that's not much more than 50-75% the diameter. You go too big and you run the risk of going at the threads and boogering up the whole thing.

Just get liquid wrench or PB blaster, let it soak overnight so it has time to get its way through the threads. Odds are this will work like a charm and you'll think that it was more in your head.


Breaking bolts happens to us all, good thing its a valve cover and not a head!!

[Levy3Poop]

I tell you what,

I have an extra E30 valve cover.

Let me try and get those bolts out if you can successfully extract them.


Just pay for shipping and they are yours. Try and extract em first tho, I dont really wanna send em off if you cant get the broken bolt out first.

You're an absolute saint! There's not even any info about that plastic piece online. I wonder if you even need it, or if the engine will run just fine without it.

It'll be tomorrow before I can try working on it again. I'll give it my best shot, and if I can't get it, I'll take it to a couple mechanics and machinists and see if anyone locally can remove it. I wonder if it's fine to just leave those bolts out if I have all the others

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[sonomabimmers]

Those reverse threaded drill bits are called easy outs. And levi they work great. Saved my ass on my old e39. First oil change I took out the drain plug and half of it was stuck in the threads. PO had over torqued it and somehow stuck the other end back on.


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[sonomabimmers]

If you can't find any I have a gang of them over here in Austin.


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[Levy3Poop]

You have a load of easy outs? Like this? I think this one is just a hair too big for the tiny screw

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[sonomabimmers]

Nope looks like this basically like a regular drill bit but with left-handed threads instead. After looking though the bulk of what I have are big ones. This looks to be the only one that might fit what you're talking about


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[Levy3Poop]

Nope looks like this basically like a regular drill bit but with left-handed threads instead. After looking though the bulk of what I have are big ones. This looks to be the only one that might fit what you're talking about


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Ahhh okay. Given the size of the bit and the size of the text on the paper, that might be too big. The bit that broke off is super retardedly small. Maybe 2mm.

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[sonomabimmers]

Yup it's gonna be to big. They definitely make them that small though. I just needed a bigger kit as it was for a drainplug. Amazon is where I found them or it was oriellys(worst store ever). One of those should be able to help you.


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[Levy3Poop]

Yup it's gonna be to big. They definitely make them that small though. I just needed a bigger kit as it was for a drainplug. Amazon is where I found them or it was oriellys(worst store ever). One of those should be able to help you.


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I'll check Amazon, thanks!

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