Guys - hoping for some help. I have an 87 4.9 i6 that I recently bought. Determined we needed a new starter. Read all the posts and watched the videos - the top bolt came out fine, the bottom one sheared right off. After trying penetrating oil and a torch to no avail, I bought both a set of bits with the reverse thread extractor and a set of the ratchets that you hammer on and they cut into the bolt as you pull. After using penetrating oil several times over days, I tried the latter. Gripped the remaining bolt head and worked great but what was left of the bolt again sheared right off. I am new to working on engines but handy, so although a little uncomfortable doing so I tried the drill and extractor. Also did not work - the bolt was so stuck that the extractor bit would just chew more of the bolt metal out. So finally after reading several posts suggesting it, I decided to just try to drill the whole thing out. And despite being pinned on the cold ground and the awkward angles, I got a hole all the way from front to back relatively straight and close to the middle, and increased the size of the bit from very small up 3 times (drill bit sizes). I now have a hole through this bolt that is so large there is not really much left - HOWEVER, I still cannot get this thing out. I have hammered on it, used a screwdriver and hammer on the small lip protruding, used a punch on that edge - and all I can succeed in doing is bending that small edge. I soaked it in penetrating oil and walked away to send this. What the heck can I do now? I really don't want to have it towed to a mechnic but this bolt seems to be one with the housing - please help! Is it time to give in?

 

If I were at that stage, I would start going up in bit sizes until I reached the size for chasing the threads with a tap. The larger bits may grb the remaining bolt shell and spin it out. At worst, you may have to tap the hole for a larger bolt or use a heli coil to repair it. Another option is to stick a smaller bolt, into the hole, and weld the new bolt to the remaining bolt.

 

thank you John - much appreciated!