Onan 4000 Intake Manifold replacement

BeeeGeee wrote:
The broken piece of bolt is in the threads by the paper towel is stuffed in the intake manifold. I was able to remove some of the air cleaner housing and have better access to the busted bolt. I may be able to Dremel a hole in the bolt enough to get a bolt extractor on it and see if it’ll unscrew out.
Thanks for everyone’s input, it’s appreciated!

Careful of bolt extractors, they are hardened and tend to snap off making drilling out the hardened extractor a near impossible job.

I suspect the leftover bolt stuck inside may be cross threaded which most likely is why it twisted off in the first place.. If cross threaded, bolt extractor failure is most likely.

Don't envy you on this, looks like a really bad position to be working on but it is most likely the only way your gonna fix it without splitting gen from engine..

on edit..

Depending on your bolt size, I would suggest perhaps a internal pipe extractor.. They tend to be much stronger than most bolt extractors..

Looks like this..



Works like this..



Have resorted to using pipe extractors on stubborn bolts in the past after seeing someone else mention them.. Can work as long as you can find one that comes close enough to work in the hole you drilled in the stuck bolt..

Don't get me wrong, I suspect even the stout short pipe extractors can break off..