I'll bet you didn't check the torque on these bolts as PM...

[KliersLC]

Little background:

While in CA in may and June of this year I was driving along at 70, took my offramp and near the bottom heard a loud bang from the front end of the truck. I was thinking caliper bolt, broken sway bar mount etc. So I pull off and everything checks out perfect. It did it several more times so I jacked up the front end and poked, prodded and pried at every moveable joint (and some non moveable ones) took off the wheels and checked the caliper bolts. Everything still checked out fine. Drained the gear oil, no shavings, checked the front u joints, no play in them or the splines. So at this point, I didn't have access to mud so I called an 80 series buddy and we decided that the only other option was a broken shock. Replaced the shocks (which needed it anyway), but that wasn't it.

So today I was puttering around the shop, installed the medium OME kit, new rotors and brakes on the rear, new wheel bearings, rotors and 100 series pads on the front, and this is what I found on the passenger side front.

 

[KliersLC]

That little bit is a broken off head that was rattling around and catching on the backside of the hub

 

[KliersLC]

The axle service wwas done at les schwab by the PO. The clowns probly overtorqued the bolts and they left a washer off on the other side...

 

[KliersLC]

So....

What to do now?

I obviously need the bolts and the backing plate, but have to get the old bolts out first. There might be one that I could realisticly get a wrench on.

Between Phaedrus and Cruiserdan the suggestions are to ice the knuckle with dry ice and use vice grips and heat in the morning, notch the bolt heads and use an impact driver, drill and use easy outs, reverse drill bit, or knock the heads off and screw them all the way into the interior of the knuckle and fish them out.

I am open to all ideas and advice.

Also, the bolts have a 7 on them, and are kinda hard to get, is it possible to get an equivalent bolt at the parts store?

thanks,
Dan

 

[Cattledog]

Drill it and use an ez-out. Buy a good $$ drill bit and the job should be easy. Buy the new bolts and lock washers from Mcmaster-Carr or similar after measuring. Replace all of the bolts....

 

[Tools R Us]

The first thing i would try is to beat a six point socket onto them and zip them with an impact. Use an old or cheap socket and grind the chamfer off of the face so the hex comes all the way to the face. If there isn't enough metal, beat on the head of the bolt, this will swell the head, then beat the socket on, broaching a new hex and zip it with the impact.

If that fails on some, get some nuts about the same size, weld them to the bolt heads and zip them off.

 

[KliersLC]

Not a bad idea, but is there a seal in there that the heat from welding will toast???

 

[Tools R Us]

Not a bad idea, but is there a seal in there that the heat from welding will toast???

If your quick with the welding, the only one that's probably in danger is the hub dust seal right there next to the bolts, I would replace that anyway. The next closest is the wipers on the other side of the housing?

 

[KliersLC]

Hmm....

I'll be getting a new backing plate anyway-there are large chunks missing from this one, so the dust seal is not an issue, I need a dust seal for the other side too.

Off to try something...... not sure what yet

thanks,
Dan

 

[landtank]

I have to remove siezed button head screws on the machine I repair professionally on a regular basis. If you don't know what a button head screw looks like, look it up on McMaster carr. Compared to those screws you've tons of surface area to work with.

My basic technique is to get a cold chisel and start by digging it in on the outer edge using a hammer. On heads that size you should have no problems driving them out. I usually have to work with 4mm size screws in areas where a good angle is tough to get.

 

[KliersLC]

Well, I got them all out. Landtank, the chisel method worked very well. thanks.
the "broke off" bolt didn't have a shaft left in the hole, so I am wondering if it backed out all the way, or if the rest of it is floating around in my knuckle somewhere.

On to more sobering news. The Les Shwab people put regular axle grease in my hubs instead of wheel bearing grease, and did the same thing to the birfs, nasty old green axle grease. Amazing. this vehicle is proof that you can take an outstanding vehicle and kill it through regular improper maintenance. I will never have service done at schwabs.

So, since I have it opened up already and the past job was poor at best, I am off to birf job land.......

Thanks,
Dan

 

[PHAEDRUS]

Glad you got them out,
keep us updated on the progress and location for the bolts.
Damn my anal retentiveness now I am going to have to pull the rotors off just to check those.
Dave

 

[matt 105]

Yep, always use a torque wrench on them.
Seen that before!