Brokenbolt

Tiny
ELKMAN6464
  • MEMBER
  • 2001 DODGE RAM
  • V8
  • 4WD
  • AUTOMATIC
  • 180 MILES
How does one extract a broken bolt out of the exhaust manifold, with broken lefthand easyout when its flush with the bolt hole.
Sunday, November 28th, 2010 AT 11:37 PM

1 Reply

Tiny
CARADIODOC
  • MECHANIC
  • 33,916 POSTS
Rig up a way to hold a nut over it, then heat the easy out as much as possible with an acetylene torch while trying to avoid heating the nut. After the easy out starts to glow orange, hit it with a wire feed welder. The goal, if you're steadier than I am, is to penetrate the easy out, THEN build up the weld to fill the nut. Sprinkle lightly with water to shrink the easy out, then use the nut to unscrew it.

I've had broken bolts that this has worked on after failing five or six times. The secret is to weld to the easy out, (or broken bolt), first before the hole in the nut fills up. The reason for heating it with the torch first is the easy out won't get hot enough to melt before the hole fills up. Then the nut just breaks off and you have to start all over.

There are also tools with four fingers that go in the slots of the easy out, supposedly to unscrew it. What they fail to realize is if it's tight enough to snap off, that dinky tool isn't going to budge it.

Caradiodoc
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Sunday, November 28th, 2010 AT 11:49 PM

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