Best way to get a broken bolt out?
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Old May 23rd, 2009, 12:44 AM   #1
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Best way to get a broken bolt out?


So, I finished polishing my valve covers the best I could (up to 2000 grit.. decent reflection) and was reinstalling. One of the bolts broke in half with part of it still in the hole where the valve cover bolts to.

What would be the best way to get this bolt out? Also.. the bolts have a metal peice they go through that holds the round black gromet in place... how do I remove the bolt from the extra metal piece?

If you have taken the valve cover off before you should know what I am talking about... if not I will take some pics.

Any help will be +reps since I really need this fixed ASAP.
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Old May 23rd, 2009, 12:46 AM   #2
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I know exactly what your talking about....We did it to the 96 taurus we're working on....Still can't get it out, so im not much help
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Old May 23rd, 2009, 12:46 AM   #3
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I have had mine off to paint them. But pics would be great!!
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Old May 23rd, 2009, 12:58 AM   #4
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Originally Posted by 1FUN4RD View Post
I have had mine off to paint them. But pics would be great!!
Will get some when I can. My main concern is getting this bolt out of there and the other half out of the adapter...

The bolt fits through a metal piece that helps hold the gasket in place. I need to get it out of that as well as the broken piece out of the engine...

I was told there is some from of tool you can buy that drills into a bolt and can drill it back out?
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Old May 23rd, 2009, 01:01 AM   #5
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You drill a hole into the center of the bolt. Then you use an easy out to remove it.
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Old May 23rd, 2009, 01:10 AM   #6
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Originally Posted by 1FUN4RD View Post
You drill a hole into the center of the bolt. Then you use an easy out to remove it.
Any tips on using it? The bolt is an 8mm head...

Any chance they sell these at auto stores, or only hardware stores?
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Old May 23rd, 2009, 01:18 AM   #7
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Sears sell them. I got mine from Bobs tools. Don't skimp out on cheap ones.

If part of the bolt is above the surface of the hole. I like to grind the top of the broken bolt flat as it makes it much easier to drill.

After you get the hole started I use oil to help the bit cut. Drill at a slow speed.

After it is drilled then as you are screwing in the easy out I tap on the easy out lightly with a hammer to help it bite into the bolt.
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Old May 23rd, 2009, 01:25 AM   #8
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Thanks for the help, gonna try and find one tomorrow morning. The bolt is below the surface sadly.

Any good way to make sure you do not drill to far?
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Old May 23rd, 2009, 01:28 AM   #9
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Put tape arround the drill bit to mark how deep you want to go.
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Old May 23rd, 2009, 02:53 PM   #10
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If the bolt isn't rusted in there, which it shouldn't be since you just installed it, you may find the bolt turns when you try to drill a hole in it. In that case a reverse direction drill bit may spin it right out.
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Old May 23rd, 2009, 05:53 PM   #11
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grab it!
thats a brand and a good cheaper extraction kit.
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Old May 23rd, 2009, 07:36 PM   #12
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I tried some today and I can not get the drill to make a hole it it... it is a small bit. Using a tool set I got from Advanced to get it out. No where around here close had any of the brands suggested.

So far... I can not get it. If I can not get it by Monday im gonna get the shop to come get the car and see if they can get it *sigh*
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Old May 24th, 2009, 11:01 AM   #13
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They sell a kit at walmart that requires you to drill a small hole down the bolt, then screw in a reverse-threaded bolt thus unscrewing the broken one.
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Old May 24th, 2009, 02:00 PM   #14
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Originally Posted by Zatrekaz View Post
I tried some today and I can not get the drill to make a hole it it... it is a small bit. Using a tool set I got from Advanced to get it out. No where around here close had any of the brands suggested.

So far... I can not get it. If I can not get it by Monday im gonna get the shop to come get the car and see if they can get it *sigh*
I'm not sure why you can't get a hole drilled. Have you tried centerpunching the broken bolt? If so you may need a harder drill bit such as a titanium one.
Another option is to get a tap in the correct thread size and drill out the old bolt with the size drill bit specified for the tap, then run the tap through to clean up the threads.
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Old May 25th, 2009, 12:22 AM   #15
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Zak it's called a knockout bit, one end drills out a hole and the other end grabs in the hole - the only thing you should have to do if the one you got didn't work is get a better one. I don't know what the bolt you broke is made of but seeing how you broke it, I'd have to think either a titanium or carbide bit should handle it.

Getting Broken Bolts Out

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Old May 25th, 2009, 12:36 AM   #16
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I got the hole drilled, but the kit I got to remove it just will not catch... Before I fuck it up even more I am getting the shop to remove it.
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Old May 26th, 2009, 12:00 PM   #17
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Car is at the shop...

$50 toe fee
$60/hr shop fee...

Looks like $110 for a fuggin bolt....

I tried getting it out for over an hour, had no luck and I seriously hope I did not mess up the threads on it. If I did I suppose they can cut new threads in it.... right?
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Old May 26th, 2009, 01:20 PM   #18
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Originally Posted by Zatrekaz View Post
I seriously hope I did not mess up the threads on it. If I did I suppose they can cut new threads in it.... right?
Yes, they shouldent have a problem making new threads in the head.
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Old May 26th, 2009, 03:10 PM   #19
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They just need to get the size drill bit for the correct size tap and drill down the center of the hole. That removes all but the threads of the old bolt and the tap will remove the threads. If that fails they can drill it out the next larger size and helicoil it back to standard size.
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Old May 26th, 2009, 03:31 PM   #20
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Originally Posted by stephen View Post
If so you may need a harder drill bit such as a titanium one.
Tungsten carbide would be better than titanium and more common. Most drill bits are actually made from tungsten carbide.

Originally Posted by Zatrekaz View Post
I tried getting it out for over an hour, had no luck and I seriously hope I did not mess up the threads on it. If I did I suppose they can cut new threads in it.... right?
If you screwed up the threads they'll just tap new ones. I personally would have drilled out the bolt and tapped new threads.
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