The thing I hate most

[jdeight]

The thing I hate most is snapping bolts in the block or head. (actually, it's the removing of snapped bolts I hate, not the snapping)

Not six weeks ago, it cost me $500 to learn the difference between red (bad) and blue (good) loctite after I snapped a bolt on the drive belt tensioner on my Lexus. In that case, I drilled a small hole and tried a screw extractor. But the screw extractor snapped off inside the bolt. That was a real mess because even carbide bits wouldn't drill out that extractor. I had to tow the car to (and from) a guy who did 'metal disintegration machining," one of two shops I found in SoCal who specialize in broken bolt extraction.

Now I'm back in the same spot again. I was trying to replace my "new" water pump on my 2000, and one of the bolts snapped. This car is new to me so there's no question of any loctite. I said a silent prayer and tried PB Blaster and vise grips. No luck. Bolt extractor: no luck. I drilled into the bolt using progressively larger bits. I've seen youtubes of guys drilling out bolts until they could remove them in pieces with needle-nose pliers. But, of course, my hole isn't dead center in the bolt, and before the bolt fell to easily removed pieces, I got nervous about damaging the block.

So I broke down and got a screw extractor. I have a 5/32" hole, and I thought a 5/32 screw extractor looked beefy enough that it wouldn't snap so easily. But... the bolt still won't budge. And, after my last experience, I'm nervous about trying too hard and snapping the extractor...

Anybody have any helpful ideas?

[ORFORD2004]

Put a nut, weld it and use ratchet to remove it.
https://www.youtube.com/watch?v=CIKmHQ2FE10

[rjkoop]

I feel your pain. Had a head bolt break off in the block and I think I went through about 8 hardened drill bits and still couldn't get it out. Broke down and called 'The Bolt Doctor' and he came over and had it done in about 15 mins. Next time I'll call him 1st!

[Nitrate]

Put some serious heat on the broken bolt before using the easy out. RB

[Exit98]

I snapped an exhaust manifold stud in the block. It was below the surface.

Did some research and ordered this set from Amazon:

http://www.amazon.com/Tools-Spiral-Extr ... YJ9323D0C5

What I liked about this set was the left hand drill bits. Anyway working slowly and deliberately I was able to get the broken stud out. The stud was otherwise clean and had been removed and put back in previously so that was a help.

As far as your concern about putting too much force on your extractor I know what you mean. Instead of twisting it can you hit it with a hammer? As you know a sharp blow is often safer and more effective than the twisting force.

Good luck, I feel your pain.

[narfire]

I like the welded nut trick. Sometimes a couple of tries required but has not let me down.....yet

[burgandy81]

Put a nut, weld it and use ratchet to remove it.
https://www.youtube.com/watch?v=CIKmHQ2FE10

+1 for this method. As heat AND gives you something to grip.

[narfire]

As mentioned, works for me...

[ORFORD2004]

As mentioned, works for me...

Why don't you hold it in your hand

[narfire]

Why don't you hold it in your hand


Not my hand.. I was the camera guy...

I had a bolt that holds the fly wheel on break . bit of a pain and took a few try's to get the weld to stick to the nut.

[JohnMc]

I used heat, PB and left handed drill bits - they finally came out.
With Easyouts you are putting pressure on the bolt - that is why I tried and liked the left handed drill bits (reverse) - and they were even at Orchard supply. https://www.youtube.com/watch?v=FYvaPbX1sT4

[jdeight]

I ended up taking it to a guy who does metal disintegration machining, specializing in broken tap removal. He got rid of the bolt, and installed a sleeve with new threads (because, of course, I had drilled mine out). PITA, but it's done.

[lglade]

Tthe bolts on my car have all surrendered without much of a fight (knock on wood ), but if I were restoring a rusty car, I'd give a serious look at a bolt heater (on eBay for about $400):

https://www.youtube.com/watch?v=MyZEaPQinO0