When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
After doing bearings, brakes, etc etc had everything back together. Last thing to do was put the Caliper Bolt / Key Retaining Screw in. Using socket wrench I got it almost in and then the head snapped off. Taking my luck to the other side of the truck, it happened again. So I now have 2 bolts with no heads on both sides of the truck that I need to get out somehow. I have tried using an extraction bit with a t-handle tap wrench with no luck. It just wont grip the bolt no matter how much I drill in and try to set it. The bolt is through the other side but there is not enough room to get anything on it and take it out that way. Im out of ideas. Would appreciate any help and if you are going to make fun of me ( rightfully so ! ) after you are done, give me some advice !
1. X2 enough sticking out to use a cut off wheel grinder and cut a flat tip screwdriver in the end?
2. Enough sticking out to put a slightly larger nut over what is left and weld it the nut to it?
3. Use a center punch and dimple a hole right In the middle (BEFORE YOU TRY METHOD 1 AND OR 2) use a Left hand Drill bit and a QUALITY EASY OUT.
4. Use the step up drill out method. Again center punch a dimple in the middle of what left, drill with the smallest bit you have and then step up a drill bit size. And again and again. DO NOT GET IN A HURRY. Continue until 90 % is gone then use a pick and break out (collapse the rest inward). Chase and clean tab the threads. And then again clean chase/tap the hole and use new none rusty old hdwr.
Some times doing it with the caliper bracket in a vice and work down on it is easier than up at and angle with it still on the truck.
Photo below. I tried EZ Out and it snapped off in the hole... So now its almost un- drillable. Not sure what my best play is here other than just replacing the caliper bracket entirely. The other side I did not have that fate so I am going to try and just drill out the bolt little by little. I dont think there is a way to extract it. The bolt is level so I am able to get the key off.
On a different tack, what about pushing the retaining key in further and drilling a new hole? Does your key have that second notch? If so, maybe you can utilize it and ignore the other one.
This snapping of bolts is FAR, FAR too common and has been since these brakes were almost new. I'm not sure what the ultimate answer is, other than to use less torque and use a thread-locker. I've personally never had the issue, but I don't have rust or such things to deal with generally either. I do use anti-seize however and have never had one back out.
Here again though, results may vary because the other thing I have heard about quite a few times is the bolts coming out!
Yes you sometime realize that cheap/cheaper tools end up making more work for you. I was removing exhaust manifold bolts....on a 351M...that was still in the truck. I broke a few bolts on each side. Then broke a cheap drill bit off in one and then broke a cheap easy out off in another.
It was a long week, I ended up using a diamond carbide bit in a Dremel and getting the broke stuff out. Then went and bought a Norseman drill bit set and easy our set from Fastenall.
Welded a quality tap in a socket and got them retapped. With the motor still in. Only had to use ONE helicoil. I never am cheap on drill bits, easy outs and beer. And now I use my good drill bits on projects then I do not want to spend a lot of time on or use my easy out set.
I'm sure with enough effort you could monkey rig something that would work, all it has to do is hold it in since it really doesn't want to come out anyway. if you don't want to replace it you might move it over enough to drill and tap it again. once you break of an extractor it's game over in that hole.
for a 2wd they're $29 each but I forgot you have a 4x4 that makes it more interesting.
Funny, I bought a carbide bit for a dremel and after what feels like 24 hours, I broke through. I still need to keep drilling on the bit and get it all out but I am making progress. My question is this : the hole is mangled. I tried a couple of turns with a tap and it didnt take. Barely turned in the hole. Any thoughts as to how to tap this ?
It is a 2wd so in hindsight I should have just bought a new bracket and saved myself 48 hours of cursing.
Use a QUALITY TAP set! If you want to stay with the same size bolt just Google "Heli-coil". If you do not mine to upsize the bolt, drill it and use the correct upsize tap.
Good luck finding a "caliper mount (support) bracket". Yes ALL the other parts are on Rock Auto for cheap, but NOT the caliper mount/support bracket. Ebay...$650 NOS.
I agree either a heli-coil or just go to the next size up bolt. all it has to do is keep it from sliding so as long as something is there for a bolt that doesn't fall out it'll do it's job.
if it's a 2wd then I'd spring for the $29 on the other side .
If you are going to try and get it, then try, either above idea. If you are going to try and drill the other 1/2 moon spot, then try, but you better get some quality drill bits for sure. I am waiting on some one to post a link to some 1974 F250 2wd single piston caliper mount brackets.
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.
