View single post by Tsquare

Posted: Thu Feb 3rd, 2022 01:14 pm

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Tsquare

Joined: Fri Nov 10th, 2017

Location: Suwanee, Georgia USA

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File or grind the top of the bolt flat. Use a center punch to put a divot in the center of the bolt. Soak in penetrating oil. If you don't have an EZ Out, the IRWIN Screw Extractor set is a good set. Select the largest EZ Out that will fit within the broken bolt and drill a hole at the divot for about a half inch. Insert EZ Out and use a Tap wrench to screw it in. That would be the direction of removing the bolt as the screw extractor will bite into the broken screw. Even cross threaded the broken bolt should come out. Once it is out use a Helicoil or Time-sert kit to put the threads back in.

Where this can go sideways is that the screw extractor brakes so you have a hardened steel core in the broken bolt. A broken bolt always makes for a bad day.

Another method is to take a nut that has the same thread pitch and screw it onto the bolt until the broken part starts to stick through. Weld up the top of the nut. Put a piece of ice on the top of the nut to temper the weld. A socket and breaker bar can be used to remove the broken bolt then it is Helicoil time.

The method I used to get a broken exhaust bolt out of a head: The EZ Out pulled part of the broken bolt out but the bolt broke a second time where it was too deep to use an EZ OUT. I pulled both heads and carried them to a machine shop to get them worked. I was quoted $1200 for the work when my buddy that owned the machine shop suggested a set of Dart Aluminum heads. The Dart heads would flow better than worked iron heads for $650.

____________________
Tony
NE ATL
'04 XLT regular cab 3.slo stepside
Semi retirement