Damnit!! Broken bolt...

[Guest]

In the process of removing my clutch cover to replace springs and pump gears, (a pictorial/tutorial is coming soon on that, Cliff, if you want to add it to your site) I snapped a case bolt off in the case. Fortunately, its the very uppermost one, so i dont think leaking will be an issue, but it bothers me, so, anyone know a GOOD way of removing that sucker?? Nothing stickin out. It snapped flush...

[Plasterdog]

http://www.asashop.org/autoinc/may2003/techtotech.htm

This may help.

[chuckycheese]

Easy Out

When I was young (and dumber), I had a bad habit of breaking off bolts so I'm pretty good at getting them out. You can buy a set of "Easy Outs" at any auto shop and, used correctly, they work great.

The first thing to do is make sure you've got the appropriate size for the bolt. Then, use a very small drill bit and drill a pilot hole in the center of the bolt. This is to minimize the likelihood of damaging the threads on the case later on. After that, move up to a bigger drill bit and expand your smaller hole in order to install the Easy Out. Drill deep enough to get a good 'bite' and then tap it into the hole until it really grabs. Carefully, put a wrench on it and gently turn it to get started. In most cases, you'll get it on your first try.

One thing I noticed through my many attempts in straightening out my foolish mistakes was that, for some reason, they usually come right out very easily. Good luck!

[rapidray]

Find a LEFT hand 1/8 inch drill bit. Center punch the bolt. Use your drill running in REVERSE & I'll bet it will back the broken part out without ever needing the easy out. A lot of guys on here like to tell you to use an easy out but a LOT of them BREAK the easy outs & if that happens, you get to be more "creative" than you want or need to. Ray.

[hikermikem]

In the process of removing my clutch cover to replace springs and pump gears, (a pictorial/tutorial is coming soon on that, Cliff, if you want to add it to your site) I snapped a case bolt off in the case. Fortunately, its the very uppermost one, so i dont think leaking will be an issue, but it bothers me, so, anyone know a GOOD way of removing that sucker?? Nothing stickin out. It snapped flush...

Hey Josh,

I don't have any luck with easy-outs, screw extractors... makes a bad situation MUCH worse.

If you know a good tig welder. weld another bolt on to what's left and then turn it right out.

The alum case won't get ruined.

[chuckycheese]

Easy outs

I must have good luck with Easy Outs due to all the experience I've had using them....... (after carelessly breaking off bolts.)

[Jethro]

If you know a good tig welder. weld another bolt on to what's left and then turn it right out.

Ding, we have a winner! That has always been the best way for me.