broken injector hold down bolts

nelsona19 · April 14, 2015

I'm doing fuel system replacement for contamination. While removing the injectors #7 & 8 injector hold down bolts broke off in the head. I was using 3/8 long ratchet to break them all loose. Both are sticking up enough to weld, so I tried that, no luck, soaked and heated also, no luck either. Any ideas?

lmorris · April 14, 2015

Replace the head if it's warranty. There is no authorized thread repair procedure in the WSM, so Ford will pay for a new head if it has warranty.

nelsona19 · April 14, 2015

not warranty, decided to pull cab to give me access to drill them out

nelsona19 · April 28, 2015

update: Well I decided to send the head out to a machine shop after having no luck drilling one out. They told us they were going to have to helicoil it and we decided to just get a new head so it would carry a service parts warranty.

May 1, 2015

I had similar problem with bolts breaking on the passenger side. I think that when egr coolers are removed, coolant leaks down the valve cover and into the bolt holes. Over time, corrosion starts and causes the problem.

Alex Bruene · June 21, 2015

I had to do one of these 2 weeks ago. I removed the cab for better access. I was able to put a good weld on the broken bolt... strong enough to rock the engine when I was trying to take it out. It wouldn't budge. I ended up having to completely drill out the bolt and retap the hole... Not looking forward to seeing too many more of these.