D20 broken bolt?

[latrucker]

I have a broken bolt in the speedo cable hold down in my D20. Tried to drill a small hole in the broken bolt and use an easy out bolt extractor. That didn't work, broke off inside the broken bolt. My next attempt will be to drill the original hole out, rethread and insert a helicoil. Not going to be easy to drill the easy out as they are HARD!!! Bolt broke 1/8" down in the hole so i have a good guide to drill a straight hole. Any thoughts or easier solutions please let me know, makes me nervous to drill into the output housing not knowing how thick it is but I don't see where I have any other options

 

[bronkenn]

If you have an automatic center punch it will chip that easy out in bits, sometimes will loosen it up too.

 

[sanndmann3]

maybe take the rear output off the transfer case and find a machine shop in the area that can edm it out.

 

[latrucker]

maybe take the rear output off the transfer case and find a machine shop in the area that can edm it out.

I removed it from the transfer case last night. What is a edm, going to call around about that tomorrow.

 

[B RON CO]

Hi, I've used a carbide Burr in a die grinder to vaporize broken bolts, drill bits, etc.
You can use a small one in a Dremel
They need to spin like 20,000 RPM.
It will turn hard steel to dust in a few seconds.
Good luck

 

[sanndmann3]

electrical discharge machining. We use it at work to remove broken drills and taps among other things... basically an electrode sparks the broken easy out, eroding it. as long as its metal it can be removed. Googling may give a better description than I have provided...

 

[Rustytruck]

Thats a pretty small bolt and easyout. You could blow it out with a plasma cutter. You could also use a grinding bit in a die grinder. You could smash the easy out with a center punch. Is the hole in the housing a through hole or a blind bottom.

 

[latrucker]

Hi, I've used a carbide Burr in a die grinder to vaporize broken bolts, drill bits, etc.
You can use a small one in a Dremel
They need to spin like 20,000 RPM.
It will turn hard steel to dust in a few seconds.
Good luck

Dremel did the job, in less than a minute it chewed it up and spit it out. Thanks for the help to you and all that responded!!!

 

[Jfryjfry]

There ain’t nuttin easy about an ezout!

 

[sanndmann3]

There ain’t nuttin easy about an ezout!

I'm not a big fan... less than 50% success for me.