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E15RCD broken bolt 1986

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paul_m_in_nj

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"While doing a new waterpump i

"While doing a new waterpump install and loosening the six bolts that connect the lower unit to the exhaust housing, one bolt snapped level with the housing nothing to grip at all. Any suggestions how to get the rest of this bolt out, they all appear to be stainless. dont want to put it back together with only five bolts holding it on. Paul NJ"
 
if your lucky you may be able

if your lucky you may be able to drill it and use an "ease out". if not you may have problems. anyone else?
 
"The best I've found so fa

"The best I've found so far, is to use a series of left handed drills. Start with the smallest gradually working your way up in size. When the one of the drills catches in the smaller hole the bolt backs right out. I've used this technique more than a dozen times and it has worked every time. I stress again to use the smallest drill bits as possible in case you start drilling out of center."
 
"I forgot an important part of

"I forgot an important part of this. DO NOT break the drill bit inside of the bolt. If this happens, you have doubled your problems. Take your time and do it right, it works perfectly."
 
"One thing that was not mentio

"One thing that was not mentioned is the importance of using a propane torch to heat the aluminum housing around any bolt that will not come loose with "normal" force. Aluminum expands at a greater rate than steel and heating the aluminum will often allow the bolt to be removed without breakage. The aluminum will absorb alot of heat and it usually takes several minutes of heating, especially on a large casting like the exhaust housing..."patience is a virtue". The heat may even help when using the left turning drill bit...remember to heat just the aluminum and not the steel...good luck"
 
"Take it to a machine shop. Y

"Take it to a machine shop. You will save so much time, trouble and $$. They have all of the fancy tools to deal with this."
 
"I am sending the web address

"I am sending the web address for the craftsmen tool catalog and the screw extractor kit. Copy and paste it and you will have all the information you need. That being said, I tend to agree with sleeper...the cost at a machine shop is probably less than the price of the tool and even with the correct tool, costly mistakes can happen especially if you have not done this before"
 
"Bob, Found a kit at sears. Dr

"Bob, Found a kit at sears. Drill bits w/ ease outs. Drilled one hole already no problem. I'm a hopeless diy er so I'm gonna get this done. I'm gonna heat the aluminum slowly before I try to ease it out, and I'm taking my time thanks to all. Paul"
 
"I buy left handed drill bits

"I buy left handed drill bits from harbor freight. Nothing wrong with easy outs, if they work. I've had them break in small bolts. Usually a broken dill bit falls out of the hole. A broken easy out has to be burned out with an edm machine. Just my opinion."
 
"Paul,I found some left handed

"Paul,I found some left handed drill bits I'm using them before the easy outs so far so good thanks for your help.Paul"
 
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