Ideas on removing a stubborn bolt?
 

I snapped a water pump bolt inside the engine block. Removed the water pump and timing chain cover. I have good access to the broken bolt, but I CANNOT get it out! Vice grips just tear it apart and drilling doesn't seem to get me anywhere (I've tried both forward and reverse bits). The bolt is currently sticking out about 1/4 ".

Any ideas on how I can get this lil' bastard out?


Also, how does one determine if a harmonic balancer is bad? Mine has very minor, hairline cracks in the rubber section, but it doesn't look like anything major.

have someone weld a bolt to it for you (portable welder) heat up the area aound the broken bolt but try not to heat the bolt directly .

if this doesnt work they have drill bit's secialy designed for people like you and me that this happens to except i spent a week drilling and trying to get one out before i found out .
it looks like a trident thing on the end it fits over the broken dolt and the drill bit is then centered and you slowly drill the bolt out untill you can get a easy out into it .

or you screw it up so bad that you have to drill everything out re tap and use a bigger bolt.

I feel for you been there done that .
oh yeah soak it in liquid wrench first

OOOOOOOOOOOOOOOHHHHHHHHH I know I know!! Tear your engine down to a bare block and put it back together with a new block and there you go. No more broken bolt!! j/k ;) :D

Wont heat cause the metal to expand? If so, wouldnt that actually make it harder to get the bolt out? I would definately try and soak it with liquid wrench. Try a real small pipe wrench. You might be able to get a bite on it.

If you can find someone that welds, welding a bolt to it is your best bet.

Whatever you do, don't forget to chase the threads of the other bolts before reassembly.

:)

Take care,
~Chris

Try heating the broken bolt and then quenching it with water. This should cause the bolt to expand and contract which should hopefully break the bolt free of the rust that is holding it in. Use never-sieze on the new bolt.

i donno about heating up and cooling, but if you heat up the block around the bolt and don't heat the bolt directly, the block will expand a tiny bit around the bolt and the bolt should be a little easier to get out. if there's a 1/4 inch sticking out, you might try grinding opposite sides of it flat and using a smaller wrench, but if it was stuck enough to break off, it probably wouldn't come out that way. Whatever you do, tell us what happens. Good luck.

Thanks for the tips, guys. I ended up just drilling the thing out and retapping the hole. I found it to be pretty scary drilling my engine block! But, everything works...