I was attempting to replace the water pump on a 1600 an I have broken the top bolt that goes into the block which holds the pump on. [:(!][:(!]

What would be the best way to extract it ?

There is approx 16mm of bolt in block with 4mm sticking out. total length of bolt is 38mm (excluding head)

I have tried to grip it with small multi grips but it tends to strip thread.

Do I try and drill it out ? I dont want to damage the thread in the block.

any suggestions will be appreciated

Aaron

drill into center of bolt and use an ezi-out. that should do it aaron

ok I drilled out the centre of bolt and now I have really f#*$d up cos the easy out thing has broken in the hole on top of bolt !!! [:(!][:(!][:(!][:(!][:(!]

I feel like a real nob now !

thanks fellas. guess i might have to head down to get an extraction kit from the cheap cheap

I might be stating the obvious here but damn its difficult to drill hardened steel !

anyone have a spare block lying around ? or a complete running 1600 ?

look up thread repair specialist in the yellow pages or google it, these people will come out to you, they have diamond tip drills which will take them about 1/4 hr from start to finish and will restore the hole back to std thread. Should cost about $150, but thats cheaper than changing blocks. I have used them for much harder jobs than water punp bolts and they have always come up tops.
PS use thread lube on the bolts when you put them back.

can you tack weld a nut on the left over bolt?

use a file and turn the remaining part of the bolt into a shape a spanner will attach to. do it carefully and keep trying the spanner as you want a tight fit. Hopefully its not so rusted in that this may help. be carefull not to score the block. You will need to file through the thread to the solid shank.
OR
cuta cross in the bolt end with a 1mm disk in a grinder then use a posi-drive impact driver to loosen it.
OR
if the easyout is shallow enough cut the offending bit off Drill it out progressively and replace the damaged block thread with a helecoil

Good luck.

JP

quote:

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Originally posted by digginganddirt

can you tack weld a nut on the left over bolt?

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I use this method fairly regularly, along with a bit of oxy torch flame to heat up the broken bolt.That helps in a lot of cases in loosening up the rusty thread. Mind you this method isnt so good if a bit of hardened eziout is still present. Can you cut the protuding bolt and eziout off flush with the block ? In my opinion, ezy outs are the devils work for small bolts !!! Be bloody careful or as been found out... it creates a lot more work . I then resort to drilling and helicoiling if the bolt is that stubborn a bit of heat wont move it. ( Might be easier all round to get a thread specialist)
Mike

There is a tool called a stud remover which might work if you have 10mm or so wticking proud. Oh BTW I have snapped cheap EZouts in bots too, damn annoying

thanks for all your advice guys

I am at the stage now where I will need professional help

After my initial attempts at removing broken piece of bolt and the broken easy out, I tried one last time at drilling them both out but found I couldn't drill it in the centre and started to damage the block, so I stopped.

I have found a thread repair guy who will drill it out and repair any damage caused by ME, for a fee of course !

I guess I have learned a valuable lesson in NOT to hang off the spanner trying to tighten up a 36 year old bolt [:I]

cheers
Aaron