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Urgent help broken bolt

Discussion in 'Z3 Roadster & Coupé' started by si-forks, Dec 17, 2011.

  1. si-forks

    si-forks Dedicated Member

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    Help needed just replacing the thermostat on my 1.9 and I've managed to snap a bottom bolt off :cry: see pic there is about 10mm of tread showing all advice welcome on the best way to get it out without doing any more damage oh the joys of working on 15 year old cars

    Sent from my GT-I9100 using Tapatalk
     

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  2. Titan

    Titan Moderator
    British Zeds

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    Re: Urgent help broken bolt

    Hi Si

    Firstly, get some WD40 on the threads pending a good answer ;)
    Secondly, I'm not sure how much room you have got to work in around that area but there are a couple of options.
    a) mole grips or b) "eazi-outs" (Typical Link)

    HTH
     
  3. NeRo

    NeRo Moderator
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    Re: Urgent help broken bolt

    If there was enough thread showing, the usual thing to do would be to put 2 nuts on the thread - then using 2 spanners turn one clockwise and the other anticlockwise. The nuts will tighten up against each other and should be strong enough to act as a bolthead
     
  4. si-forks

    si-forks Dedicated Member

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    Thanks for that only got myself to blame rushing !!! Got it soaking in WD 40 will leave it for a few days

    Sent from my GT-I9100 using Tapatalk
     
  5. Macca

    Macca Zorg Guru (II)
    Supporter British Zeds East Anglian Crew

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    Re: Urgent help broken bolt

    You want to try one of these.

    http://www.ebay.co.uk/itm/DRAPER-200MM- ... 1912wt_982

    The more you tighten the bigger the grip. I've used one on broken threads before and never failed to get a bolt out as long as you have enough thread showing. P.S. Its a good idea to use WD40 or some form of penitrating fluid as well.
     
  6. si-forks

    si-forks Dedicated Member

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    Re: Urgent help broken bolt

    Thanks for all the advice s:D s:D will keep you posted on the outcome S:smile
     
  7. gelertd1

    gelertd1 Regular Member

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    Re: Urgent help broken bolt

    Look on the bright side - at least it didn't snap off flush!

    Often had this happen when changing the thermostat on 'A' series engines in Mini's etc - it was always the last of the three that sheared off :ymsigh:

    Macca's suggestion is good, the tool allows more leverage than mole grips, hopefully you will have enough room to use it. If room is tight you could try one of these.....

    http://www.machinemart.co.uk/shop/produ ... ractor-set

    ideal where access is tight - use a socket with a ratchet, harder you turn the ratchet the harder the extractor bites onto what remains of the stud. Hopefully you have enough of the broken stud protruding so you can use these.

    Often a good idea to try and tighten the stud slightly before trying to 'back' it out - when it does begin to move, gradually back it out by tightening then loosening and so on, gradually increasing the amount of movement each time - and spray the WD40 in as you do.

    Consider a sharp 'tap' on the head of the broken stud (not too hard) with a hammer before you start, sometimes the shock can break the corrosion that often 'welds' the fastener.

    I have welded a nut onto the top of the remains of a broken stud - but this depends on access and where the offending stud is located. The benefit of this 'trick' is the heat involved often frees the fastener.

    There are better penetrating fluids out there than WD40, good though it is, WD40 is more of an 'all rounder'. I use 'Wickes' penetrating fluid or 'Duck Oil'.

    As already suggested, whatever you use, soak it for a couple of days before trying.
     
  8. Frank.A

    Frank.A Zorg Addict

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    Re: Urgent help broken bolt

    Plus Gas is the Daddy of all penetrating fluids and really works.After all WD40 is only fish oil. ;)
     
  9. WeeJimmy

    WeeJimmy Regular Member

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    Re: Urgent help broken bolt

    PlusGas and a little heat from a butane burner (gentle heat required as the housing is aluminium) is a good start.

    It looks like you may be able to cut a slot in the bolt with a hacksaw, and use a well-fitting flat-bladed screwdriver. Torqueing the driver to undo and tapping it at the same time with a hammer is often successful. I wouldn't use an impact hammer as the screw looks too small.

    If that fails, I'd try Mole-grips. Make sure the grip is very tight. This is really a one chance optioin, so you want it to work.

    If the bolt breaks flush, file it flat, centre punch it and drill down its length. Start with a small drill and then get gradually bigger. Eventually, you will be able to bend the bolt's thread into the hole. Eventually, you can remove all the bits of the screw. Clean the thread with a tap.

    Eazi-outs are OK until you snap one. If that happens, you are screwed.

    PlusGas is far superior to WD40.
     
  10. si-forks

    si-forks Dedicated Member

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    Thanks for the tips some great advice on broken bolt removal this tread should go over to knowledge base :grin:

    Si-forks on tapatalk
     
  11. si-forks

    si-forks Dedicated Member

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    The bolt is out after a week of sweating about it and spraying it with oil. finally got it out this morning !!! Tried the double nut method with no luck and ended up hammering a small socket on the end about 5mm and then slowly turning with a rachet , with a crack it was out

    Si-forks on tapatalk
     

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  12. GazHyde

    GazHyde The Gaz Monkey
    Staff Member Administrator Global Moderator British Zeds

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    Re: Urgent help broken bolt

    Good work Si, perseverance seems to have paid off. Wish I had your patience...
     
  13. Titan

    Titan Moderator
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    Re: Urgent help broken bolt

    I suggest this be recorded either as the "knock-a-socket-on-it" method \:D/
    or
    Instead of "sock it to me baby" how about "socket-to-me-w(r)ench"?

    Either way, glad you got it out Si - Merry Xmas S:smile
     
  14. gelertd1

    gelertd1 Regular Member

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    Re: Urgent help broken bolt

    A 'sweet' moment when you hear and feel the 'crack' as it gives up.

    Job done :ymapplause:
     
  15. hard top

    hard top Zorg Expert (I)
    Dutch Zeds The M44 Massive

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    Re: Urgent help broken bolt

    Titan, should you not be at work?

    ai890.photobucket.com_albums_ac102_mikehartplanetnl_Bad_Varney_1.jpg

    s:lol
     

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