3.5L EcoBoost Exhaust Manifold Broken Bolt User Guide Text
Exhaust Manifold Repair (EMR)
With PowerDrive Accessory
Thank you for your purchase of a ProMAXX® engineered performance device! Our tools have the highest quality and precision in the market, delivering the most productive repair. All ProMAXX® tools are manufactured in the United States of America from American materials and craftsmanship. We proudly provide limited lifetime warranties and free unlimited technical support. If you need help with a repair, call us! You can reach ProMAXX® Technical Support at 724-941-0941.
- Mount the ProPlate™ to the cylinder head using the ProFasteners (PMXPPF008500) according to the enclosed cylinder head schematic. Torque ProFasteners to a minimum of 20 FT-LBS.
- Start with the smallest ProBushing™ and insert into the ProPlate™. Insert the corresponding ProDrill™ machine grade tooling bit into an air-powered, angled-style drill. Using drill depth gauge machined into the ProPlate™. Set the proper depth of the bit and mark as necessary. Apply one drop of ProLube™ (PMXPPL001) to the end of the bit. AVOID USING PENETRATING OIL/SPRAY OR OTHER LUBRICANTS WHICH ELEVATE CUTTING EDGE TEMPERATURES CAUSING THE BIT TO BURN AND CEASE CUTTING.
- Attach the included PowerDrive PMXPDT250 to your 1/4" air ratchet or using the adapter to attach it to a standard 3/8” or ½” drill. You can also attach the PowerDrive to the ProMaxx® ProRatchet PMXPPR5260 or ProDrill PMXPPD2800PRO. The included drill bits PMXPSSC125 / PMXPSSC188 / PMXPSSC266 will screw directly into the PowerDrive accessory or ProDrill PMXPPD2800PRO.
- SET THE CUTTING EDGE: While applying light pressure, activate your drill both on and off five times in one-second intervals (ten times if utilizing an air ratchet). This is the MOST CRITICAL step of this repair, creating precise alignment (a seat) for the tooling bit to stay on center and not follow the angular broken surface of the stud; apply load evenly across the entire cutting edge. Once seated, drill continuously at the proper RPM (speed chart Included with your kit).
- EXTRACTOR OPTION: Prepare to Extract Remnant. Remove the ProPlate™ and if your kit included the optional ProCutter™ deburring tool, (PMXPPC007A), then replace the ProDrill™ with the ProCutter™. Insert the protruding portion of the arbor into drilled hole. Toggle the drill on and off for five one-second intervals to remove the burr, clean the tapped hole, and flatten the broken stud. With ProTractor™ (PMXPPT125 or 188), place a mark approximately ¼” from the end and lightly hammer the ProTractor™ into the remnant to the ¼” depth line. DO NOT INSERT THE PROTRACTOR ANY FURTHER THAN 1/4" depth line. Place the included slip-nut over the ProTractor™ and slide it up against the cylinder head. While holding the opposite end of the ProTractor™ and using a high-quality calibrated torque wrench, slowly and carefully apply torque, first in the clockwise direction, and then in the counterclockwise direction to loosen the damaged stud. Repeat this motion three or four times with caution NOT EXCEEDING 75 IN-LBS FOR THE PMXPPT125, or 135 IN-LBS FOR THE PMXPPT188.
- EXTRACTORLESS™ TOOLING OPTION: If you purchased the EXTRACTORLESS™ option with or added to your EMR kit, you have the option to
Remove with an extractor OR go EXTRACTORLESS™ drilling out the broken remnant. For EXTRACTORLESS™, follow the sequence of the PMXPSSC125/188/266 for an aluminum head, or PMXPSSC125/188/270 for a cast iron head drill steps. When finished drilling, insert the tap ProBushing™ into the mounted ProPlate™ and use the ProTap PMXPPT008 to chase the threads clean. Apply one drop of ProLube PMXPPL001 to each flute of the ProTap. Turn one full turn of the ProTap when you begin, then turn counterclockwise 1/4-1/2 turn frequently. Using compressed air, clean the cutting debris free by sending compressed air down each flute of the tap to remove any remaining material. This step will remove obstacles in the threads to reduce the probability of tap failure.
NOTE: In the unlikely event an extractor fails or a tap breaks, contact technical support at 724-941-0941 for recommendations and procedures. (ProMAXX® Broken Extractor kits available at www.promaxxtool.com)
NOTE: ProMAXX® does not recommend tapered left-handed screw extractors as they have the potential to deform the remnant in the cylinder head increasing the complexity of extraction. In addition, these extractors cannot be turned clockwise to unlock the damaged remnant. See the included drill chart with recommended operating RPM for each step and tooling bit size.
NOTE: Some air ratchets may not generate sufficient RPM under load to be effective. Visit www.promaxxtool.com to see ProMAXX® drilling solutions for optimum efficiency and maximum productivity: ProRatchet PMXPPR5260 OR PowerDrill™ PMXPPD2800PRO
All PROMAXX® machine-grade tooling is made in the USA and is specially engineered to close tolerances of (+) .000” and (-) .001”. They are ground straight to ensure accurate and repeatable results, reducing walk and increasing efficiency when completing these repairs.
Specify PROMAXX® genuine replacement parts and tooling for optimum performance and extended warranty coverage. Always use appropriate OSHA-approved safety glasses/goggle and protective gloves while using this device and performing this operation.
Elizabeth II User Guide
3.5L EcoBoost Turbo Broken Bolt User Guide Text
FORD 3.5L ECOBOOST EXHAUST MANIFOLD SAVER REMOVE BOLT TOOL
PMXEMS200B
The ProMaxx® ProPlate™ included in this kit was designed to be used with Extractorless(TM) tooling to assist in repairing the exhaust manifold rather than replacing it due to broken bolts on the turbo mounting flange. The EMS200A is a ProPlate-only add-on for your 200 Series ProKit. All of the tooling from your other 200 Series ProKits (3.5L EcoBoost-Elizabeth, Ford Modular-Rocky, 6.7L Power Stroke-Payton, etc.) will be used to complete this repair.
- Remove any portion of the fastener that protrudes above the surface of the exhaust manifold prior to mounting the ProPlate. Insert the flange side into the Turbo passage in the exhaust manifold carefully centering the bushing mounting hole over the damaged 8MM tapped hole/damaged bolt(s). Using a 9/16” deep socket and ratchet or boxed end wrench, tighten the chrome hex nut until the ProBody™ stops moving. Once stable, turn an additional one-half turn or more until the ProBody™ assembly is firmly secure to the manifold.
- Insert the PMXPPB2125 ProBushing™ and PMXSSSC125 or PMXPLTV125 ProDrill™ tooling bit into an air-powered drill.
- Open the cap on your ProLube™ and insert the small tooling bit through the cap, gasket, and retract. The bottle is designed to deliver the precise amount of oil necessary for the operation. For larger tooling and subsequent machining, use just one drop placed on the end of the ProDrill™ when necessary. AVOID PENETRATING OIL/SPRAY OR OTHER LUBRICANTS.
- Insert the mounted ProDrill™ into the ProBushing™ first by slowly and manually turning the chuck until the ProDrill™ slips into the bushing and contacts the surface of the damaged stud. This will ensure the cutting edge is maintained. While applying light pressure, activate your drill both on and off in approximately one-second intervals for ten seconds.
- This initial process is critical in that it creates a “seat” for the bit to rest and ensures that the bit will stay on center and not follow the angular surface of the damaged bolt/stud. Moreover, this action reduces the probability of the tooling bit to break and drill off center.
- Proceed to drill continuously at the proper RPM as provided below. Gradually apply more pressure and while the bit is turning, extract the bit slightly in and out sufficiently enough, maintaining it in the bushing to allow the bit to “clean” cutting debris from this operation. Repeat this step frequently while continuing to apply more pressure until the drill chuck rests on the bushing.
- Remove PMXPPB2125 ProBushing™ (SML) and replace with the PMXPPB2188 (MED) and follow with the PMXSSSC188 ProDrill™ using the same procedure as above, manually inserting the ProDrill into the bushing by hand and then start and stop your drill on and off prior to drilling continuously.
- Remove PMXPPB2188 ProBushing™ (MED) and replace with the PMXPPB2266(LRG) and follow with the PMXSSSC266 ProDrill™ using the same procedure as above, manually inserting the ProDrill into the bushing by hand and then start and stop your drill on and off prior to drilling continuously.
- Blow the debris clean. Remove PMXPPB2266 ProBushing™ (LRG) and replace with the PMXPPB2320 ProBushing™ (TAP). Place one drop of ProLube™ drill and tap-cutting lubricant on the PPT008 ProTap™ and proceed to insert the tap into the bushing. Slowly begin to restore the threads by turning the tap at ¼ revolution intervals clockwise and counter-clockwise periodically stopping to blow debris from the tap through the flutes of the tap. Removing the tap is not necessary. Continue to clean the threads until the tap stops. DO NOT OVER-TORQUE TAP. In the unlikely event a tap fractures, visit www.promaxxtool. com and purchase the ProTap™ extractor kit.
For technical support, visit www.promaxxtool.com, or contact us via email at info@promaxxtool.com or call 724-941-0941. The tooling included in your kit are precision-machine grade quality made in the USA and engineered as a complete system to ensure complete success and repair of the cylinder head without cylinder head removal. Be sure to specify ProMAXX® machine tooling when replacement is necessary.
USE ONLY GENUINE PROMAXX® MACHINE GRADE PARTS. Tooling cutting speeds (Under load):
MIN: PMXSSSC125@350 RPM, PMXSSSC188@200, PMXSSSC266@150.
MAX: PMXSSSC125 @900 RPM, PMXSSSC188@300, PMXSSSC266@250.
OPTIMUM: PMXSSSC125/PMXSSSC @600 RPM, PMXSSSC188@250, PMXSSSC266@200.
PROMAXX® TOOLING IS SPECIALLY ENGINEERED TO CLOSE TOLERANCES (+) .000” AND (-) .002” TO ENSURE ACCURATE AND REPEATABLE RESULTS USING YOUR NEW DEVICE. SPECIFY PROMAXX® GENUINE REPLACEMENT PARTS AND TOOLING FOR OPTIMUM PERFORMANCE AND EXTENDED WARRANTY
