Transmission cross member issue.

[Dyehard]

PO broke three of the bolts off on passenger side of the frame mounted bracket that attaches the crossmember to the frame. It only had one bolt holding it up. I have tried everything I know to remove the broken bolts but I can't get them out. I have soaked them in PB Blaster, I have heated them, and my bolt extractors are on the verge of breaking when I try to use them. I am thinking about drilling out the bolts but if I do that I will have to drill out the threaded sleeve that is attached inside the frame. Will nutserts be strong enough to use at this location? Any other suggestions? Any help will be greatly appreciated.

 

[DirtDonk]

I would think just about anything would be strong enough because the stress is in shear, not "yank" ;D (or whatever a pulling force is called!)%)

I just drilled and threaded the holes directly into the frame material for my factory skid plate and have literally pivoted the Bronco on it many times.
That said, it's not the same as a drivetrain crossmember/support I realize. But with four larger size bolts on each side, I'd say you have some leeway in strength.

If in doubt, are there any access holes nearby that you could use to insert a nut-plate or four individual nuts and washers to reinforce the attaching points?

Paul

 

[JSBX]

You could try welding a nut to the broke off bolts and then back them out. This has worked for me on different situations. You can also try to drill them out with left hand drill bits. Start off with a small bit and sometimes this will help free them up before you get to large bit.

 

[Dyehard]

The bolts are broken off too deep in the hole to weld a nut. I think at this point I will use some 3/8" nutserts because like Paul said shear weight won't be much of an issue. Thanks guys.

 

[73azbronco]

Small drill bit and step up, old bolt will basically come apart and then clean threads it should still be usable.

 

[71 CA Bronco]

Small drill bit and step up, old bolt will basically come apart and then clean threads it should still be usable.

Times 2. Center punch the bolts. start small and slowly work up to a bit size just smaller than the threads. Once the bolt is removed then clean threads with a tab. I had a bunch like this during my frame off. It worked nearly every time. Even if you jack up the threads you could probably oversize the hole after and re-tap new threads. Probably will not be necessary though.

 

[pcf_mark]

While the bolts are in sheer while sitting, engine off, they are in tension when the driveline is trying "twist" to drive the wheels. There are 8 of them which is a lot compared to a lot of other trucks or cars (GM uses 2 per side!). I agree with trying to drill them out. Even if they are off a little or you foul the threads a bit you can clean them up and have the extra metal thickness of the backing plate / insert the factory used.

 

[73azbronco]

Dont use those stupid bits with a centering part on the tip, hate those things.

 

[fordguy]

Take your time, be patient and they will come out if you start small and work up to larger bit. Once they get thin enough you can tap them out with a small chisel/punch. It will take hours possibly. Center punch before you start drilling.

 

[Dyehard]

Just wanted to thank you all for the guidance. I did like most of you suggested and started with a small drill bit and stepped up till I could re-thread the hole with a tap. Looks like I'm finally ready to get this transmission back in its home. Thanks again.

 

[sanndmann3]

Good that you are making progress! my luck is such that hole always goes off center and ends up trashing threads...

 

[Dyehard]

Well I won't guarantee that I stayed perfectly straight while drilling but, like PFC_Mark said, there is enough material there that you can still get good threads and I ran a 1/2" drill bit through the holes in the bracket so that I had some wiggle room if I did go in a little crooked.

 

[dhobby25]

I’m having a pretty big issue with these cross member bolts. How do I go about getting broken titanium drill bits out of the bolts? Should I purchase carbide bit?

 

[DirtDonk]

Interesting issue. And not the first time we’ve experienced it!
Sorry, I don’t remember the general solutions, but enough of us have had to deal with it here that I feel certain someone will come up with a good answer for you. Or at least a string of good answers that you can attempt to try.
Meantime, welcome to the site! I see you’re not actually “new” here, but new to posting about an issue.
Sorry you’re having trouble, but we should be able to help you out.

 

[Broncobowsher]

I’m having a pretty big issue with these cross member bolts. How do I go about getting broken titanium drill bits out of the bolts? Should I purchase carbide bit?

The titanium bits are not really titanium. They are regular tool steel bits with a titanium based coating on them. So getting them out is pretty much like any other drill bit extraction. Heat is the enemy of a drill bit, they loose there heat treatment.

 

[dhobby25]

So heating them up will make them softer?