In attempting an oil cooler replacement / EGR delete yesterday and today I cannot manage to break free the right turbo mounting bolt (while looking from the front of the truck). I shot it with PB Blaster and a couple other penetrating oils and still no luck. I think it is starting to strip so I even tried using one of those spiral sockets for stripped bolts, no luck. A 10mm 6 pt wrench spins, even a 3/8" does not fit well enough to break it loose, plus there is absolutely no room to get a decent pull on it back there. Any ideas on how to get it out of there?

 

Sounds like you're in the process of rounding off the head of the bolt, and one of the worst places/bolts to do it on to boot.

Figure out the best wrench for the job (there are a lot of bolt extraction type wrenches out there) and make sure you've got a really good bite with it and then heat the bolt up with a blow torch. Might help to hit the bolt with an air hammer first just to knock everything around a bit.

If all else fails you might have to Dremel the head off or drill the bolt from the front of the truck side and then chuck up a dull drill bit and hope the dull bit bites inside the new hole and turns it out but that's worst case.

 

Mine had to get a back one dremaled and dont do it

they have a bolt remover at sears you could try the size for the bolt head due to bolt head design it usually will bottom out so thise size not the best

BUT IF THAT DONT WORK they have a deep one that you go over te bolt and SLEAVE
I Cant remember but you need like a 16-17-18mm DEEP one to go OVER THE SLEAVE BOLT ALL



and my truck will NEVER have that back bolt in again anti seize the new bolts

 

Even if I dremel the bolt head off, how do I get the rest of the bolt out of the hole? Aren't the turbo pedestal and housing both threaded?

 

Sometimes it's possible to break a bolt loose by tightening it. The corners won't be rounded in the tightening direction and as soon as it moves the SLIGHTEST amount, try n back it out then.

 

I know the turbo is threaded on the front two bolts but not sure about the rear bolt.

 

I always used a 10mm rachet wrench on the turbo bolts....

I hate that bolt, its hard to get with a 10mm socket and a 3/8's universal.

Goodluck, let us know how you make out

 

From there it would be easy to just pull the pedestal out and use an easy-out to back the threaded portion left in the EDIT: turbo out. The biggest problem is the location of the bolt in question so once you get the turbo out and on your bench it's easy.

 

use a quaility striped bolt socket for 10mm an impact wobble and 8-10" 3/8 extension. hammer it on the bolt and remove with an impact gun.
you can also try to heat it with a flame wrench

 

Snap On sells a wrench for about $27 that's specifically designed for this bolt. Yes it's a wrench for the 6.0 diesel turbo. Part number PSWT10K. I didn't know until I did strip the bolt. I used the Sears spiral bolt remover and it worked perfect.

Here's a link that may help.

Ford Powerstroke Diesel Turbo Wrench, No. PSWT10K from Snap-on

Good luck.

 

If you have to I have taken a pair of vise grips and clamped them on the engine to get a good ground, then take a stick welder and crank it up, get a large rod and stick it, to the head of the bolt leave it for about 1 minute, that will heat the bolt and break down the rust. Do it with penetrating oil on it. Go have a coffee or other beverage and then remove it. Works for Me!

 

Just make sure all the electronics are disconnected first.

 

I second this. Thats worked for me many times but I have had one that I could not get out that was on a 03 the one on the back left and ended up removing the turbo and pedestal together. It sucked to get both those out but it is possible

 

on an 03/ early 04 use a 17mm extractor

 

No the pedestal is not threaded the turbo exhaust housing is.