Ok I need a really good failsafe method to remove the remains of a bolt that was broke off in the tailshaft housing. It's a ferous bolt, in an aluminum housing, thus causing the problem I'm sure. It's only one, the other 5 came out fine(prolly why this one broke becuase my head was gettin swollen) Im sure the tranny is usable without it, but I'd rather have it if I can. Thanks in advance.

 

Depends on whether it's broken off flush, has some bolt sticking out, etc. Can you stick an appropriately sized nut over the end of the broken bolt, plug weld it and unscrew? Heat (in moderation) always helps. Easy-outs rarely work. You could very carefully drill out the shank and clean up the threads with a tap or re-tap oversize. You can drill out and install a Heli-coil.

 

The remains of the bolt are below the surface of the case, by about 1/8" you can access the rear of the case as well, and the end of the bolt is about 1/4" from the surface there. I didn't think heat would be a good idea, being that the case is alum...

 

Then it looks like drilling is the answer. You might have better luck going from the back side since the end of the bolt should be flat. Center punch then drill with something small like 1/8 inch. Work your way up in drill bit sizes until you're close to the minor diameter of the bolt threads. Sometimes at this point the bolt will shrink in enough to be able to pick it out. You can also try running the right size taper tap into the hole in the bolt. This sometimes will wind the remains out.

If it were me, I'd just drill the sucker clean out, and install a Heli-coil and be done with it.

Steel fasteners into threaded holes in aluminum. That's why they invented Loctite 40 years ago.

 

Try soaking it in somekind of penetrating oil. I reccomend Kroil brand if you can get it. Then try drilling it out with a left hand drill bit. Some times they will catch and back the broke bolt out while drilling.

 

Use the candle trick on the Garage forum FAQ. Very little heat is needed. Slot the end of the bolt with a Dremel cut off wheel. Make sure the slot does not form a leak path thru the gasket or seal.

 

Us Rednecks would use a torch.

 

US rednecks that have used a torch know that it's not too friendly to aluminum I will try the slotted trick- so just heat it up, slot an screw it out eh? okiedoke

 

Check your other thread on the same subject.

 

Here is where to get it.
http://www.kanolabs.com/

Great stuff, It is the best penetrating oil I have ever used.

 

where can I get 'kroil' OTC, w/o having to order it?

 

Check with your local industrial supply place if you have one in your area. If not it is worth ordering. Great stuff.

 

A candle is simple and available, sits in a drawer until needed, does not lose pressure...

 

Hey Eric where do you find the "garage forum" FAQ. I think I am too dense this morning to find it. I assume there is a step by step method in there for the candle trick. Thanks.

 

Try reading my sig maybe?