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I have a dana 44 front with the bolt on lock outs and all the bolt broke off inside the hub. Now can i drill out the bolts and retapp or do i have to buy a new hub?
I would think that you can drill them out and be on your way. If you get a set of small easy outs, and just drill the center of the bolt for the smallest easy out, the bolt should come out. A hint, cobalt tipped bits are the best for bolts. Or, you can try another method, and that is get a left handed drill bit. Often they will catch and spin the bolt out.
If you are talking about the 8 little bolts that hold down the locking cap/hub to the spindle, missing just one will not make much of a difference in strength since they are not subject to a lot of stress. They are meant to hold on, not prevent rotation.
If you have an aftermarket hub it might be an aluminum bolt and they are fairly easy to remove with a left hand drill bit. The problem is they are usually 1/8 and the bolt is about that.
Remove the hub and see if there is enough of the bolt left to get a vise grip on or to turn it with a small drift.
If the bolt was aluminum and broke fairly clean with the surface, take a #1 phillips bit screwdriver, pound it into the screw, and try turning it out. Once it is turned out a bit, use visegrips the rest of the way.
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