Need help removing bolt in rear end - The 1947 - Present Chevrolet & GMC Truck Message Board Network

c10crazy · 01-18-2006, 05:31 PM

What is the best way to remove a bolt from the rear diff cover??. The head broke off 2 years ago and now the cover leaks. I want to get that bolt out first.

67Fleet · 01-18-2006, 06:19 PM

drill it out and re-tap it, or use a special tool called Bolt-Out or something. I know there's something out there to remove busted studs.

see ten · 01-18-2006, 06:21 PM

I have cut a slot in the top of broken bolts with a grinder and backed them out with a screwdriver.

PanelDeland · 01-18-2006, 06:32 PM

If cutting a slot does not work you can use an E-Z out.You will need to drill the center of the bolt and tap it in.Then just screw it out.DO NOT BREAK THE E-Z OUT!!!!They are too hard to drill and a real pain to get out.You may need to ask for a bolt extractor unless you're talking to someone who knows nomenclature.I got a small set at sears years ago for about $10.00.Drills included.

Bowtie67 · 01-18-2006, 07:00 PM

my guess would be that when putting the bolt in was over tightened and broke, what i have done and had great succes with is super glueing another bolt to it and just unscrew it, Unless the bolt was cross theeaded in or it was to long and bottomed out it will usually come out.

**pjmoreland** · 01-18-2006, 07:06 PM

Did the bolt head break off when you were tightening it or when you were loosening it? In my experience if a bolt breaks off while trying to loosen it, it's jammed in the threads. If the head wasn't strong enough to get the bolt out, then an easy-out isn't going to be strong enough either. In that case, your best bet will be to drill the bolt out on center with the biggest drill bit you can use that won't damage the threads, and then use a tap to remove the rest. If the bolt broke off because you overtightened it, then an easy-out might work.

**VetteVet** · 01-18-2006, 09:17 PM

If you can get to the bolt from the inside after removing the cover then you may be able to get a pair of small vise grips on the threads and back it out enough to get it out from the outside.

carl609 · 01-18-2006, 10:25 PM

I have removed a lot of broken bolts and have probably tried every tool. not so easy-outs work sometimes but if you break it you are screwed. the most effective way I have found is with a welder. take a similar sized bolt and grind a 45 degree angle at the bottom to make room for the weld. get a good weld on it and back it out. make sure not to accidentaly weld the broken bolt into whatever it is in. good luck

jamesi20 · 01-18-2006, 10:32 PM

I have had real good success with left handed drils...just center punch the broken bolt real good and use a cordless drill at the slow setting.9 out of ten times the drill will grab the bolt and back it out.the drills can be bought at harbor freight for $5.99 for a set of 5 drills.we do this at work all the time

al's71gmc · 01-18-2006, 10:33 PM

similar to what carl609 said, but i have used a nut instead of a bolt. make sure the hole in the nut is equal or slightly small than the diameter of the broken bolt. hold it in place and weld down thru the nut. i think it's easier than a bolt/less chance of welding to the case. just used this a while back on the transfer case shifter bolt with great success. god luck,
Al

c10crazy · 01-18-2006, 10:47 PM

Thanks for all the suggestions!. I installed a cheap chrome cover and used the bolts that came with it and over tightened one

.

67chevemall · 01-19-2006, 11:33 AM

WD 40 then heat everything but the bolt, and back it out with ez out
or grinder screw driver....

01-18-2006, 05:31 PM	#1
c10crazy Like a Rock! Join Date: May 2002 Location: USA Posts: 1,092	Need help removing bolt in rear end What is the best way to remove a bolt from the rear diff cover??. The head broke off 2 years ago and now the cover leaks. I want to get that bolt out first. __________________ 69 LWB Runs great - work in progress Mess with me and you mess with the whole trailer park!

01-18-2006, 06:19 PM	#2
67Fleet Outlandish Trends - FL Join Date: Jul 2005 Location: Orlando Posts: 1,396	Re: Need help removing bolt in rear end drill it out and re-tap it, or use a special tool called Bolt-Out or something. I know there's something out there to remove busted studs. __________________ -Bret 67 short-fleet sold!

01-18-2006, 06:21 PM	#3
see ten WTB this ad Join Date: Sep 2004 Location: Lafayette Georgia Posts: 5,074	Re: Need help removing bolt in rear end I have cut a slot in the top of broken bolts with a grinder and backed them out with a screwdriver.

01-18-2006, 06:32 PM	#4
PanelDeland I am a Referee of life. Join Date: Jun 2000 Location: Greensboro N.C. Posts: 13,993	Re: Need help removing bolt in rear end If cutting a slot does not work you can use an E-Z out.You will need to drill the center of the bolt and tap it in.Then just screw it out.DO NOT BREAK THE E-Z OUT!!!!They are too hard to drill and a real pain to get out.You may need to ask for a bolt extractor unless you're talking to someone who knows nomenclature.I got a small set at sears years ago for about $10.00.Drills included. __________________ The 47-present Chevrolet and GMC Truck Message Board Network,it's owners,moderators,members,and associates of any type should not be held responsible for my opinion. You can't fix stupid,not even with duct tape. "My appearance is due to the fact that "GOD" does punish you for having too much fun!" Barrett-Jackson has perfected alchemy,they make rust into gold! "You can lead a horse to water but you can't saddle a duck" "Cleverly disguised as a 'Responsible Adult' "Sometimes your Knight in shining armor is just a retard in tinfoil" Last edited by PanelDeland; 01-18-2006 at 06:33 PM.

01-18-2006, 07:00 PM	#5
Bowtie67 Registered User Join Date: Jan 2004 Location: NH Posts: 2,266	Re: Need help removing bolt in rear end my guess would be that when putting the bolt in was over tightened and broke, what i have done and had great succes with is super glueing another bolt to it and just unscrew it, Unless the bolt was cross theeaded in or it was to long and bottomed out it will usually come out. __________________ 1967 C10 - SWBSS Pro Street 427sbc, 700R4 & 4.10 Gears 1948 Chevy FleetMaster Coupe, LS1, (almost done) 1950 Chevy StyleLine Coupe 250/6 3x2 Dueces 2009 Toyota Tundra 1996 Harley RoadKing "I maybe getting old, but I can still burn rubber with the best of them"

01-18-2006, 07:06 PM	#6
pjmoreland Senior Member Join Date: Jan 2005 Location: CA Posts: 5,786	Re: Need help removing bolt in rear end Did the bolt head break off when you were tightening it or when you were loosening it? In my experience if a bolt breaks off while trying to loosen it, it's jammed in the threads. If the head wasn't strong enough to get the bolt out, then an easy-out isn't going to be strong enough either. In that case, your best bet will be to drill the bolt out on center with the biggest drill bit you can use that won't damage the threads, and then use a tap to remove the rest. If the bolt broke off because you overtightened it, then an easy-out might work.

01-18-2006, 09:17 PM	#7
VetteVet Msgt USAF Ret Join Date: Jan 2005 Location: Kalamazoo, Michigan Posts: 8,717	Re: Need help removing bolt in rear end If you can get to the bolt from the inside after removing the cover then you may be able to get a pair of small vise grips on the threads and back it out enough to get it out from the outside. __________________ VetteVet metallic green 67 stepside 74 corvette convertible 1965 Harley sportster 1995 Harley wide glide Growing old is hell, but it beats the alternative.

01-18-2006, 10:25 PM	#8
carl609 Registered User Join Date: Jan 2006 Location: Lynnwood, WA Posts: 63	Re: Need help removing bolt in rear end I have removed a lot of broken bolts and have probably tried every tool. not so easy-outs work sometimes but if you break it you are screwed. the most effective way I have found is with a welder. take a similar sized bolt and grind a 45 degree angle at the bottom to make room for the weld. get a good weld on it and back it out. make sure not to accidentaly weld the broken bolt into whatever it is in. good luck

01-18-2006, 10:32 PM	#9
jamesi20 Senior Member Join Date: May 2002 Location: NORTHEAST OHIO Posts: 493	Re: Need help removing bolt in rear end I have had real good success with left handed drils...just center punch the broken bolt real good and use a cordless drill at the slow setting.9 out of ten times the drill will grab the bolt and back it out.the drills can be bought at harbor freight for $5.99 for a set of 5 drills.we do this at work all the time

01-18-2006, 10:33 PM	#10
al's71gmc 4 eyed fever Join Date: Jul 2005 Location: Eureka, Nevada Posts: 500	Re: Need help removing bolt in rear end similar to what carl609 said, but i have used a nut instead of a bolt. make sure the hole in the nut is equal or slightly small than the diameter of the broken bolt. hold it in place and weld down thru the nut. i think it's easier than a bolt/less chance of welding to the case. just used this a while back on the transfer case shifter bolt with great success. god luck, Al __________________ 1971 GMC 2500 4x4 1972 GMC Sierra Grande 1/2 t 4x4-#1 son's truck. Recently completed resto. 4 YO daughter," Daddy, I like your truck better than Mom's." (2000 F350-ranch truck) Smart kid!!

01-18-2006, 10:47 PM	#11
c10crazy Like a Rock! Join Date: May 2002 Location: USA Posts: 1,092	Re: Need help removing bolt in rear end Thanks for all the suggestions!. I installed a cheap chrome cover and used the bolts that came with it and over tightened one . __________________ 69 LWB Runs great - work in progress Mess with me and you mess with the whole trailer park!

01-19-2006, 11:33 AM	#12
67chevemall Registered User Join Date: Apr 2003 Location: NB Posts: 3,367	Re: Need help removing bolt in rear end WD 40 then heat everything but the bolt, and back it out with ez out or grinder screw driver.... __________________ 1968 Chevy C10 307 3ott fleetside 1967 Chevy C/10 V8, 3spd, fleetside lwb.Sold 1967 Chev C/10 step, 383, M21. SOLD

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