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techtalk:evo:engmech03a [2019/08/01 04:05] hippysmack [Using stud removal tools to loosen the stud] |
techtalk:evo:engmech03a [2024/01/03 20:54] (current) hippysmack |
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| ====== Cylinder / Head Bolt Issues and Repair ====== | ====== Cylinder / Head Bolt Issues and Repair ====== | ||
| ===== Sub Documents ===== | ===== Sub Documents ===== | ||
| - | See also [[techtalk:evo:engmech03b|Time-Sert Repair on Engine Case Cylinder / Head Stud Hole]] in the Sportsterpedia for cylinder / head stud repair. | + | See also in the Sportsterpedia: |
| - | + | * [[techtalk:evo:engmech03b|Time-Sert Repair on Engine Case Cylinder / Head Stud Hole]] | |
| + | * [[techtalk:ref:tools023#warped_or_damaged_thread_repair|Warped or Damaged Thread Repair]] | ||
| ===== Loose Head Bolt Studs ===== | ===== Loose Head Bolt Studs ===== | ||
| A big concern about the studs becoming loose is the threads being stripped in the case. \\ | A big concern about the studs becoming loose is the threads being stripped in the case. \\ | ||
| The two side by side bolt holes on the right side in the pic below are each drilled into the opposing holes and tapped. \\ | The two side by side bolt holes on the right side in the pic below are each drilled into the opposing holes and tapped. \\ | ||
| So each hole is depending, in part, of the strength of the other. \\ | So each hole is depending, in part, of the strength of the other. \\ | ||
| - | With the bolts loosening, it is at least suspect that the threads or the hole strength is compromised. ((Hippysmack of the XLFORUM http://xlforum.net/forums/showthread.php?t=2074117&page=2)) \\ | + | With the bolts loosening, it is at least suspect that the threads or the hole strength is compromised. ((Hippysmack of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/197474-leaking-head-gasket-loose-head-bolts/page2?t=2074117&page=2)) \\ |
| - | | Weakest head stud holes in the case. ((photo by Hippysmack)) | | + | | Weakest head stud holes in the case. ((photo by Hippysmack)) | Head bolt pulled out of the case. ((photo by Blue Scoot of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/198541-repairing-cylinder-studs-cases/page5#post4360678)) | |
| - | |{{:techtalk:evo:engmech:weakest_cylinder_bolt_threads_by_hippysmack.jpg?direct&300|}}| | + | |{{:techtalk:evo:engmech:weakest_cylinder_bolt_threads_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:head_bolt_pulled_out_by_blue_scoot.jpg?direct&300|}}| |
| There is a procedure in the manual for tightening the studs before installing the cylinders and heads. \\ | There is a procedure in the manual for tightening the studs before installing the cylinders and heads. \\ | ||
| Line 25: | Line 25: | ||
| If a stud is backing out, it could have simply be from it being installed improperly to begin with. \\ | If a stud is backing out, it could have simply be from it being installed improperly to begin with. \\ | ||
| It is possible that the stud turned when the head cap nuts were removed. \\ | It is possible that the stud turned when the head cap nuts were removed. \\ | ||
| - | Heat plays a role in what happens to the studs / nuts also and can lock the cap screw tighter than the stud is to the case. | + | Heat plays a role in what happens to the studs / nuts also and can lock the cap screw tighter than the stud is to the case. \\ |
| So it is possible that the top nut was just tight to the stud before breaking loose. \\ | So it is possible that the top nut was just tight to the stud before breaking loose. \\ | ||
| First try and remove any studs that back out and check the threads in the case as well as the stud. \\ | First try and remove any studs that back out and check the threads in the case as well as the stud. \\ | ||
| Line 38: | Line 38: | ||
| This will also cause a leak if not done properly. \\ | This will also cause a leak if not done properly. \\ | ||
| \\ | \\ | ||
| + | |||
| + | ==== Soaking the threads for easier removal ==== | ||
| + | Soaking the threads is usually advised before attempting to remove them. \\ | ||
| + | Due to the angle of the block, it's not possible to actually leave anything next to the threads since it will simply slide down the block. \\ | ||
| + | So a 'holding chamber' was made to let the oil sit and penetrate the threads. \\ | ||
| + | |||
| + | The block was cleaned of oil and wiped down with acetone on a rag. \\ | ||
| + | The a small piece PVC pipe was silicone to the block and let cure. \\ | ||
| + | Lube oil (in this case cutting oil) was poured into the PVC to soak the stud threads overnight. \\ | ||
| + | This made removing the stud with an 18" pipe wrench easier the next day. \\ | ||
| + | {{:techtalk:evo:engmech:stuck_cylinder_stud_removal_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) | ||
| + | |||
| ===== Stud Removal ===== | ===== Stud Removal ===== | ||
| ==== Using stud removal tools to loosen the stud ==== | ==== Using stud removal tools to loosen the stud ==== | ||
| - | |||
| |{{:techtalk:evo:engmech:bent_socket_ext_while_removing_cylinder_stud_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:broken_stud_extractor_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:damaged_cylinder_stud_while_removing_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:bent_socket_ext_while_removing_cylinder_stud_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:broken_stud_extractor_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:engmech:damaged_cylinder_stud_while_removing_by_hippysmack.jpg?direct&300|}}| | ||
| - | |||
| ==== Using a pipe wrench to loosen the stud ==== | ==== Using a pipe wrench to loosen the stud ==== | ||
| + | |||
| + | A propane torch works well to melt or loosen old Loctite (red or blue) on the threads. \\ | ||
| Catch the stud down low, but not so low as to run the wrench into the block. \\ | Catch the stud down low, but not so low as to run the wrench into the block. \\ | ||
| Line 59: | Line 71: | ||
| The pipe wrench is mainly to break torque. It's easier to get out of hand and damage something if it's not needed after that. \\ | The pipe wrench is mainly to break torque. It's easier to get out of hand and damage something if it's not needed after that. \\ | ||
| - | ===== Stripped Case Threads ===== | + | If the pipe wrench slips, you may need to adjust the wrench so the stud is closer to the inside teeth. \\ |
| + | You may need to loosen the jaws to move the stud back. \\ | ||
| + | The wrench doesn't have to be tight against the stud to grip. \\ | ||
| + | It works by the magic of binding onto the stud. \\ | ||
| + | It's important to hold center on the wrench and stud with one hand. \\ | ||
| + | You can try getting a grip by tilting the handle up with just a little pressure and then back level. \\ | ||
| + | You just have to find a way to make the wrench bind against the stud. \\ | ||
| + | |If the wrench doesn't grip, make it bind on the stud. ((photo by Blue Scoot of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/197474-leaking-head-gasket-loose-head-bolts/page6?t=2074117&highlight=head+gasket&page=6)) | | ||
| + | |{{:techtalk:evo:engmech:removing_cylinder_stud_with_pipe_wrench_by_blue_scoot.jpg?direct&300|}}| | ||
| + | |||
| + | ==== Using Double Nuts / Jam Nuts ==== | ||
| + | Install 2 nuts on the top threads and torque the two nuts to 35ft pounds or higher. \\ | ||
| + | Be aware the tall studs can stretch if it takes too much torque to break them free. \\ | ||
| + | Be sure to use rags around the bore so as to not get any debris in the engine while removing the stud(s). \\ | ||
| + | |||
| + | | Three jam nuts used here. ((photo by A 4 liter V8 eater of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/148266-building-a-90-inch-sledge-hammer/page11#post3236162))| | ||
| + | |{{:techtalk:evo:engmech:tightening_cylinder_-_head_studs_by_a_4_liter_v8_eater.png?direct&300|}}| | ||
| + | |||
| + | ===== Cleaning the Case Threads ===== | ||
| + | The threads on the head studs as well as in the case need to be clean and free of rust / debris and they need to be straight in order to obtain proper torque on the heads. \\ | ||
| + | |||
| + | The photos below are of before (L) and after (R) chasing the case threads with a 3/8"x16 tap. \\ | ||
| + | The dirty threads will add preload to the torque readings and can easily give false readings on the wrench which could affect head gasket performance. \\ | ||
| + | |||
| + | {{:techtalk:evo:engmech:head_bolt_threads_before_chasing_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) {{:techtalk:evo:engmech:head_bolt_threads_chased_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\ | ||
| + | |||
| + | ===== Stripped Case Threads ===== | ||
| These could be repaired with Heli-coils. \\ | These could be repaired with Heli-coils. \\ | ||
| But the repair must be straight with no wobble when drilling. \\ | But the repair must be straight with no wobble when drilling. \\ | ||
