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Old 08-28-2010, 07:12 PM   #1
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Broke transfer case bolt removal - seeking ideas

I broke a transfer case bolt while trying to install a t-case drop with the lift kit a few weeks ago. I have done the following to try to remove the bolt with negative results so far:

hammered the frame area around the bollt in hopes of breaking some rust free

used a scrap bolt and aligned it with the broken bolt and hammered it in hopes of breaking rust free

got an easy-out kit - drilled through the bolt completely (you got to respect the strength of a grade 8 bolt) and wore out three drill bit and broke one too,

I have PB Blasted through the drilled out bolt so the PB Blaster can setlle down inside the frame on the broken bolt

the easy -out has a square head that is not compatable with standard or metric wrenches so I have tried an adjustable wrench and a vise grip, neither are breaking loose the bolt and both are slipping off the easy-out

I tried a tap wrench but the easy-out is slipping in it too and the bolt continues to resist

i used a propane torch and tried to heat up the bolt while attempting all of the above also

Should I heat the bolt until it is glowing orange hot and try again??

any suggestions from anyone?? I am out of ideas and about out of beer so I am begging here

I do not have an acetylin torch nor a welder and there is not enough exposed bolt to weld an nut on anyway

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Old 08-28-2010, 08:38 PM   #2
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that blows dude, can you post a picture?

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Old 08-28-2010, 08:51 PM   #3
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Can you keep increasing the size of the drillbit to take out more and more of the bolt without going all the way to the threads and get a ezout in there? Or you might just have to drill it out refill the hole and drill and retap it.
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Old 08-28-2010, 09:03 PM   #4
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I usually tap the easy out into the hole good and then use a socket on the square end of the easy out - I just go with as beefy a 12 point socket as I can find that fits then use a ratchet to turn the easy out - Ive had some luck this way b4 - that and the welding a nut on trick but u already said u cant do that. good luck
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Old 08-29-2010, 04:57 AM   #5
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Had same broblem with my temp guage sender (the rear one) had to drill it out and retap hole. (pity you cant sell rust as a bonding agent).
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Old 08-29-2010, 11:32 AM   #6
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Quote:
Originally Posted by Gate53 View Post
Can you keep increasing the size of the drillbit to take out more and more of the bolt without going all the way to the threads and get a ezout in there? Or you might just have to drill it out refill the hole and drill and retap it.
This is the procedure I have been trying. I have the bolt drilled out to the largest bit diameter in the easy-out kit and have tried the easy-out bit but cannot get anything to maintain a good grip on the easy-out and cannot get the broken bolt to start to break free.
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Old 08-29-2010, 05:48 PM   #7
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are you talking about one of the six belly pan bolts? or on the actual transfer case? I'm confused.

if it's the belly pan, i've had three of those break before. lots of fun.
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Old 08-29-2010, 06:50 PM   #8
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So JG how did you get your belly pan bolts out. I have one that is snapped and I am still unable to get it out.
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Old 08-29-2010, 09:34 PM   #9
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I finally got the bolt out, sort of. I ended up using a #5 ezout size from my set which matched up to an 11/16 drill bit. I heated the bolt up until smoke was rolling out of the other access holes in the frame. I hammered the ezout up into the drilled out bolt, found that an 8 point 3/8" socket could be forced onto the end of the ezout and used a bf pipe over the socket wrench for extra force. The nutsert broke free and the bolt was loose but still would not drop out of the frame.

I then put a vice grip on the bottom of the ezout and was wiggling it back and forth while pulling downward trying to get the whole thing out of the frame. All of a sudden the vice grip pulled off the end of the ezout and poof, the bolt and ezout all disappeared. Never heard anything hit the floor and never found the ezout or bolt. It was like a Criss Angel Mind Freak moment.

The ezout and bolt now have to be up in the frame but i could not feel or see it in any way. I figure if I ever sell the Jeep I will have to add another $8.00 to the sale price to cover the cost of the ezout tool I am providing inside the frame.
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Old 08-29-2010, 10:12 PM   #10
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haha jeez what a nightmare
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Old 08-29-2010, 10:17 PM   #11
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Glad to hear that you got it Semi-out lol I wonder if it was in a bind and that's what caused all this.
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Old 08-30-2010, 09:22 AM   #12
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Hey Mustache...thanks for telling me how you got that bolt out. Now I know I am in for a fight against rust, metal and my Jeep. Good to hear you got it out.

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