gd... broken bolts!!!

[rusty turd]

Well here is my dilemma

Yesterday I decided to fix a seeping oil leak from the side panel in my FJ60... I broke one bolt off in the worst possible place... bottom left corner bolt...

Dilemma 1... now I have a huge leak

Dilemma 2... bolt's in a place I can't fit a drill

Dilemma 3... I believe there is not much of the bolt sticking out cuz the head from it there's about a thread and a half but I'll know for sure later tonight when I get home

So my question is this...

How the hell am I going to get that bolt out of there... if there isn't enough to grab on to...

I'm open to suggestions... I'm sure somebody has broken a important bolt on their fj's in tight place before....

I was thinking if I a dab of oh s*** weld let it cure....

 

[brian]

probably have to pull the side cover off completely. that should/could reveil enough of the fastener to get a vice grip on.

 

[StevoJonesFJ60]

Have any pictures of the break?

 

[hank14]

I don't know for sure how you're going to do it, but I remembered this thread and thought I'd reference it:

https://forum.ih8mud.com/60-series-...ide-cover-gasket-replacement.html#post6325872

 

[Kurtis]

I would pull that side cover off like brian said. Clean it really really really well so there is nothing to burn and then heat the area around the bolt with a torch and it will come right out with a vice grips. Or you can go rent an angle drill and use an easy out but I would defiantly still heat up the surrounding area before using the easy out. Honestly heat is the best thing with stuck bolts. It will make the most stuck bolt turn right out.

 

[StevoJonesFJ60]

I definitely agree with heat, also penetrating oil becomes your best friend on old trucks like ours.

 

[lovetoski]

A side-angle drill can be a life-saver in cases like this. Be careful though that it's one which works well. The first one I bought was poor quality...the tip of the drill-bit wandered in a small circle...very difficult to drill out a broken bolt!

Heat + penetrating oil + time + patience...you'll get that bad boy outta there.

 

[daveIT]

Can you Dremel a slot into it and maybe use a stubby flathead screwdriver on it?

 

[Elbert]

if you have enough room to grab it with vise grips......get it hot with torch...and it should come out. I've seen all kind of stuff that you could not budge and it walks right out once heat is applied. THe bad deal is if the bolt breaks below the surface of teh boss area and then you have a real problem..

Other idea is to weld a nut to the the bolt and then apply heat to the area.

Heat is your friend but be safe with the application of the heat an other things under teh hood...like fuel lines..

 

[csd4682]

AHHH! I feel your pain on this. I now have a new to me, low mileage 2f in my truck from this exact same problem. I broke the same bolt. I bought a good angle drill attachment and about 100 bucks worth of drill out and reverse thread bits to try and drill it out. After about 4 hours I finally was able to get a good hole going that was going to allow me to go up in size on the bits slowly and the re-tap, then right before I go to pull the bit and go to a larger size the bit broke inside and I was never able to get it out. I am very happy that I replaced my motor as it had over 300k on in and my new one only has 130k but all I can tell you is to try everything you can to get the bolt out. I have never had any luck with those drill outs, but the reverse thread drill bits seemed like they may have done the trick if I had not buggered things up first with the drill outs. As far as the angle drill, I bought mine from sears for around 25.00 and it goes on the end of a regular drill. It worked ok but was just a touch big to get a straight on approach. Good luck. I feel your pain. I hope you are able to get it out. Keep us posted.

 

[slacker24-7]

nothing i hate more than to feel that bolt let go.. would a regular angle drill take up less room than a attatchment? and a short bit. i had broken the exhaust manifold bolt closest to the fire wall and heat really helped me get that out along with having enough thread for vicegrips.. maybe ya can drill it and use a ez out WITH heat applied ... that jb weld will just break loose its strong , but not that strong
sorry man, that kinda thing really sux !!!

 

[rusty turd]

Ok... what a cluster...

I tried everything a 90* drill attachment and several drill bits...

I had what I thought was a big/n deep enough hole drilled into the bolt. I put a easy out on it put 1 turn on it and broke the GD easy out in the bolt...

So went to the depot rented a pneumatic 90* drill and started to drill out the easy out and broke the GD drill bit off inside the easy out...

So... because this is my DD right now I had to take this side cover on and off so many friggin times I could do it in the dark...

This is what I did...
I bought all new bolts and a tube of getto weld, some rtv sealer some sand paper, wire brush and some brake cleaner...

I cleaned the living hell out of the block and side cover put a bead of rtv sealant from the mid bolt closest to the fire wall to the mid bolt closest to the water pump of the cover and a larger bead of cold weld along the bottom... installed loosely with bolts tightened every HR or so then let it set over night...

And wahla...
no more seeping oil leak

However I would not recommend this fix if u plan on keeping, rebuilding, or coring your f engines..

This fix will make your core unusable and u will pay dearly for it..

I'm not keeping mine for long...
My 2f is on its last leg... and a 350 will be going in its place

 

[Skniper]

Glad it's holding...yep, you pretty much hit the clusterf*ck trifecta when you broke the drill bit off IN the easy out!! You gotta be like a nuerosurgeon using those things.

I replaced my fj62 side cover gasket several years ago....I was about to just shoot myself during that ordeal.
I thought it would a quick and easy deal so I didn't bother removing the entire right side of the engine bay like I should have....I had hell trying to get the cover back in with the gasket flopping all over the place.

 

[ntsqd]

E-Z-Outs are misnamed.

Those with the spiral flutes should be outlawed.

 

[augirthedude]

6 mm bolts should not be torqued over 12 ft/lbs . For broken rt. handed bolts I have had good luck with a left handed drill bit ....

 

[rusty turd]

E-Z-Outs are misnamed.

Those with the spiral flutes should be outlawed.

I sure wish I would have known that
cuz that is exactly what used...

GD broken bolts... that bolt is not the first to break on my cruiser... I know it won't be the last either...

 

[brian]

left handed drill bits.....easy out and a drill bit all in one handy package.