PowerTech Set – Echo PMX240PRO Kit Includes
ProPlate Ford Gas/Diesel (4.6L, 5.4L, 6.8L Gas / 6.0, 6.4L Diesel) - PMXRII200
ProPlate Ford Gas 6 cyl. Transit 3.5L & 3.5L ECO Transit, 150, Navigator - PMXEII200
Extractorless, with PowerDrive Adapter - PMXPDT250
ProPlate Fasteners - PMXPPF008500
ProBushing - PMXPPB2125, PMXPPB2188, 2266, 2320
Threaded Cobalt Drill Bits - SSC125T, SSC188, PMXPSSC266-STD
ProDrill Platinum - PMXPLT188
Drill Bit Adapters - PMXPSSC125ADP125, PMXPSSC125ADP188
ProTap Bottom Tap - 8mm X 125 - PMXPPT0080125
Threaded Countersink/Chamfer – PMXPSSCCTSK
ProLube Drill/Tapping Fluid - PMXPPL001
Not Included But STRONGLY RECOMMEND POWERCUT - PMXPMXPWC188 Premium Platinum Tooling Endmill
PowerTech Set – Echo PMX245PRO Kit Includes
ProPlate Ford Gas/Diesel (4.6L,5.4L,6.8L Gas / 6.0, 6.4L Diesel) - PMXRII200
ProPlate Ford Gas 6 cyl. Transit 3.5L & 3.5L ECO Transit, 150, Navigator - PMXEII200
Extractorless, with ProChuck – PMXPPC250A
PD Chuck Adapter ¼ x 28 TPI .375 Dia. X .75 - PMXPSSCADPTR
ProPlate Fasteners - PMXPPF008500
ProBushing - PMXPPB2125, PMXPPB2188, PMXPPB2266, PMXPPB2320
Threaded Cobalt Drill Bits - PMXPSSC188-STD, PMXPSSC266-STD
ProDrill Platinum - PMXPLT188
Drill Bit Adapter - PMXPSSC188-ADP
ProTap Bottom Tap - 8mm X 125 - PMXPPT0080125
Threaded Countersink/Chamfer – PMXPSSCCTSK
ProLube Drill/Tapping Fluid - PMXPPL001
Not Included But STRONGLY RECOMMEND POWERCUT - PMXPMXPWC188 Premium Platinum Tooling Endmill
60-Second Video: EcoBoost Broken Bolt Repair
VIDEO
—EXHAUST MANIFOLD BOLT REPAIR VIDEO—-Ford EcoBoost 3.5L Remove broken exhaust manifold studs / bolts. For Ford F-150 and Ford Transit. Made In USA. Twin turbochargers, broken titanium bolts, small engine bays, along with dimensional changes in the cast iron manifolds due to extreme heat create new problems for the servicing technician.
Instructions for Use with PowerDrive
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 airpowered, 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 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 complexity of extraction. In addition, these extractors cannot be turned clockwise to unlock the damaged remnant.
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 are 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.
Instructions for Use with Drill Chuck
Instructions Exhaust Manifold Repair w/Drill Chuck
Congratulations on 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. Need help with the repair? Contact ProMAXX Technical Support @ 724-941-0941
Mount the ProPlate™ to the cylinder head using the included ProFasteners (PPF008375 or PPF008500) according to the enclosed cylinder head schematic. Torque ProFasteners to a minimum of 20 FT-LBS.
Insert the ProBushing™ into the ProPlate™. Then insert the corresponding ProDrill™ machine grade tooling bit (included) into an air-powered, angled-style drill. Using drill depth gauge, machined into the ProPlate™, set the proper depth of the bit and mark if necessary. Apply one drop of ProLube™ (PPL001). AVOID USING PENETRATING OIL/SPRAY OR OTHER LUBRICANTS WHICH ELEVATE CUTTING EDGE TEMPERATURES CAUSING THE BIT TO BURN AND CEASE CUTTING.
Insert the prepared ProDrill™ into the mounted ProBushing™ by slowly and manually turning the drill chuck until the ProDrill™ slips into the bushing and makes contact with the surface of the damaged stud. (This will ensure the cutting edge is not damaged.) *Repeat this procedure for each sequential step in your application.
SET THE CUTTING EDGE: Important step to avoid drill bit breakage. 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. Moreover, this step allows the surface of the stud to conform to the cutting edge of the bit, distributing the load evenly across the entire cutting edge, which is essential for cutting extremely hard surfaces and extending the life of the cutting tool.
After Step 4, run drill continuously at proper RPM (see cutting speeds below). While the bit is turning, slightly extract the bit in and out of the damaged stud to “clean” or “excavate” cutting debris from the stud (commonly referred to as peck drilling). Repeat this step progressively, exerting more pressure until the drill reaches the marked depth.
Inserting ProTractor (PPT125): Remove the ProPlate™ and place the optional ProCutter (PPC007A) in the drill. Insert the protruding portion of the arbor into drilled hole. Toggle the drill on and off five times to remove the burr and clean the tapped hole. With ProTractor (PPT125), place a mark approximately ¼” from the end and lightly hammer the ProTractor (PPT125) 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 several times NOT EXCEEDING 75 IN-LBS OF TORQUE FOR THE PPT125 OR 150 IN-LBS FOR THE PPT188. If the damaged stud fails to release, STOP and remove the ProTractor™ and proceed to the next step.
Inserting ProTractor PPT188): using the larger (optional) ProDrill™ and corresponding ProBushing™, repeat steps 3-5 to prepare in using the larger extractor (PPT118). NOTE: In the unlikely event an extractor fails or breaks, contact technical support at 724-941-0941 for recommendations and procedures. ProKits can also be upgraded to be an “extractorless” repair: Repeating drilling instructions above and chasing threads clean with a machine-grade tap.
NOTE: ProMAXX® does not recommend tapered left-handed screw extractors as they have the potential to deform the remnant in the cylinder head increasing complexity of extraction. In addition, these extractors cannot be turned clockwise to unlock the damaged remnant. Approximate tooling cutting speeds (Under load): MIN: SSSC125/PLT125@500 RPM, SSSC188/PLT188@300, SSSC266/270/ PLT270@250.
NOTE: Some air ratchets may not generate sufficient RPM under load to be effective. See ProMAXX® ProRatchet PPR5260 or PowerDrill™ PPD2800 at www.promaxxtool.com for optimum efficiency and maximum productivity.
PROMAXX™ machine grade tooling is specially engineered to close tolerances of (+) .000” and (-) .001” and ground straight to ensure accurate and repeatable results in using your new device. 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.
