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Option to secure coil pack with broken stud

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2005 955 S w/~127K


I recently replaced my coil packs (my first time this deep in to this car) which ended up being a great idea as it solved a very odd electrical problem (different thread) but whoever replaced the plugs last used a pneumatic driver or something to screw the bolts in to the head that hold down the coil packs.  One of the studs was cross threaded, two more somewhat cross-threaded, and one of the studs was broken off flush with the head. Idiot! It wasn't me... i swear.


Funny thing is I have been riding around with it like this for a year or so... with nothing but friction holding the coil pack down..

But it really bugs me for it to be that way so I decided to try to remove the broken stud after a few drinks and one youtube video that made it look easy and a chearp harbor freight extractor.

It actually was going quite well until i broke off the extractor in the hole, and then a drill bit trying to remove the extractor, and then everything went to hell two more drinks later and I really farted up the whole thing beyond repair... Idiot!


What to do?


Can this brass insert be removed without removing the head?

should i have a machine shop or something drill out the bolt in to the brass area (margins) and re-thread it?

can i have someone just weld a small aluminum anchor on either side of the coil pack to put some wire over the top of the coil pack to keep it down?

high temp jb weld for instead of welding?

glue the coil pack to the head?

just leave it as-is?


Don't really care what i looks like... just don't want to have it come loose on me.






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I feel for you.  I'm normally over on the 996 forum but this is purely a mechanical problem.  Since the coil pack is mostly retained by the tight fit in the spark plug hole, and since you are mostly concerned about it vibrating loose, I would grind the bolt part flush with the flat brass insert with a Dremel grinding disc (small enough to do the job), then use a dab of some silicone glue on the brass insert to hold the coil pack.  It is amazing how well it holds, and is completely removable the next time.  There are two bolts that hold in the coil pack, so how is the other coil pack bolt?

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Guys, enough with the weird work around Magiver repairs; if you cannot drill the bolt and remove it, you need to drill out the insert and install a new one, but this time put some antiseize on the fasteners and this will never happen again.

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  • 2 weeks later...

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