Best method for extracting bolts with broken off heads...
 

So I'm elbows-deep in pulling out my radiator and water pump from my '88
Jeep Comanche (4.0l, if that matters), and as I figured was likely, two bolt
heads broke off. I've got pictures, if you care to see
(http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're broken
off just under the head, so there's about 1/2" of threaded material to grab,
assuming that doesn't break off.

What's the best method you've found to deal with these? Do any of them work
better than others? If I've got to drill a hole in them, how do you get the
hole started with an uneven surface like the broken off head? Center-punch?
That'll be fun to get in there with a hammer...

So far, I figure I'm about 3 hours into the job, and I've got all the old
parts out. The old water pump actually looks like it's in good shaped
(vanes all there, looking pretty new), but it was leaking. There was no
sign of anything other than the paper gasket; should I be using the RTV
gasket gunk as well? Somehow, I've got to get into the block heater and
replace it as well. At least with the water pump out, I can see in there a
bit.

Clint

Re: Best method for extracting bolts with broken off heads...
 

Clint wrote:
> So I'm elbows-deep in pulling out my radiator and water pump from my
> '88 Jeep Comanche (4.0l, if that matters), and as I figured was
> likely, two bolt heads broke off. I've got pictures, if you care to
> see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're broken off just under the head, so there's about 1/2" of
> threaded material to grab, assuming that doesn't break off.

ow

> What's the best method you've found to deal with these? Do any of
> them work better than others? If I've got to drill a hole in them,
> how do you get the hole started with an uneven surface like the
> broken off head? Center-punch? That'll be fun to get in there with a
> hammer...

I hate dealing with stuck bolts, But you might have enough to get
vice grips on. Hit it with some PB blaster, tap the head with
a hammer a few times, and try. Sears has extractor sockets that
have left hand threads and might work. Similar to these
http://us.st11.yimg.com/us.st.yimg.c...1925_917971002

If they break off flat it's drill time. I use a center punch but
sometimes a dremmel will be good enough. Just watch you don't
destroy the threads.

As for the gasket, just make sure it's clean and use the paper gasket.
Any other stuff in there just sets you up for future leaks.

--
DougW

Re: Best method for extracting bolts with broken off heads...
 

Clint wrote:
> So I'm elbows-deep in pulling out my radiator and water pump from my
> '88 Jeep Comanche (4.0l, if that matters), and as I figured was
> likely, two bolt heads broke off. I've got pictures, if you care to
> see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're broken off just under the head, so there's about 1/2" of
> threaded material to grab, assuming that doesn't break off.

ow

> What's the best method you've found to deal with these? Do any of
> them work better than others? If I've got to drill a hole in them,
> how do you get the hole started with an uneven surface like the
> broken off head? Center-punch? That'll be fun to get in there with a
> hammer...

I hate dealing with stuck bolts, But you might have enough to get
vice grips on. Hit it with some PB blaster, tap the head with
a hammer a few times, and try. Sears has extractor sockets that
have left hand threads and might work. Similar to these
http://us.st11.yimg.com/us.st.yimg.c...1925_917971002

If they break off flat it's drill time. I use a center punch but
sometimes a dremmel will be good enough. Just watch you don't
destroy the threads.

As for the gasket, just make sure it's clean and use the paper gasket.
Any other stuff in there just sets you up for future leaks.

--
DougW

Re: Best method for extracting bolts with broken off heads...
 

Clint wrote:
> So I'm elbows-deep in pulling out my radiator and water pump from my
> '88 Jeep Comanche (4.0l, if that matters), and as I figured was
> likely, two bolt heads broke off. I've got pictures, if you care to
> see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're broken off just under the head, so there's about 1/2" of
> threaded material to grab, assuming that doesn't break off.

ow

> What's the best method you've found to deal with these? Do any of
> them work better than others? If I've got to drill a hole in them,
> how do you get the hole started with an uneven surface like the
> broken off head? Center-punch? That'll be fun to get in there with a
> hammer...

I hate dealing with stuck bolts, But you might have enough to get
vice grips on. Hit it with some PB blaster, tap the head with
a hammer a few times, and try. Sears has extractor sockets that
have left hand threads and might work. Similar to these
http://us.st11.yimg.com/us.st.yimg.c...1925_917971002

If they break off flat it's drill time. I use a center punch but
sometimes a dremmel will be good enough. Just watch you don't
destroy the threads.

As for the gasket, just make sure it's clean and use the paper gasket.
Any other stuff in there just sets you up for future leaks.

--
DougW

Re: Best method for extracting bolts with broken off heads...
 

Looking at your picture you "might" be able to get PB in the back of the
bolt through where the water pump goes. Also I find that heat from a propane
torch then pb blaster then more heat and again pb helps. The trick is not
to mess up what you've got to grab onto. So try pb, heat and pb first.

JoBo

"Clint" <cneufeld@mysocks.shaw.ca> wrote in message
news:UJCkh.535564$R63.397938@pd7urf1no...
> So I'm elbows-deep in pulling out my radiator and water pump from my '88
> Jeep Comanche (4.0l, if that matters), and as I figured was likely, two
> bolt heads broke off. I've got pictures, if you care to see
> (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
> broken off just under the head, so there's about 1/2" of threaded material
> to grab, assuming that doesn't break off.
>
> What's the best method you've found to deal with these? Do any of them
> work better than others? If I've got to drill a hole in them, how do you
> get the hole started with an uneven surface like the broken off head?
> Center-punch? That'll be fun to get in there with a hammer...
>
> So far, I figure I'm about 3 hours into the job, and I've got all the old
> parts out. The old water pump actually looks like it's in good shaped
> (vanes all there, looking pretty new), but it was leaking. There was no
> sign of anything other than the paper gasket; should I be using the RTV
> gasket gunk as well? Somehow, I've got to get into the block heater and
> replace it as well. At least with the water pump out, I can see in there
> a bit.
>
> Clint

Re: Best method for extracting bolts with broken off heads...
 

Looking at your picture you "might" be able to get PB in the back of the
bolt through where the water pump goes. Also I find that heat from a propane
torch then pb blaster then more heat and again pb helps. The trick is not
to mess up what you've got to grab onto. So try pb, heat and pb first.

JoBo

"Clint" <cneufeld@mysocks.shaw.ca> wrote in message
news:UJCkh.535564$R63.397938@pd7urf1no...
> So I'm elbows-deep in pulling out my radiator and water pump from my '88
> Jeep Comanche (4.0l, if that matters), and as I figured was likely, two
> bolt heads broke off. I've got pictures, if you care to see
> (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
> broken off just under the head, so there's about 1/2" of threaded material
> to grab, assuming that doesn't break off.
>
> What's the best method you've found to deal with these? Do any of them
> work better than others? If I've got to drill a hole in them, how do you
> get the hole started with an uneven surface like the broken off head?
> Center-punch? That'll be fun to get in there with a hammer...
>
> So far, I figure I'm about 3 hours into the job, and I've got all the old
> parts out. The old water pump actually looks like it's in good shaped
> (vanes all there, looking pretty new), but it was leaking. There was no
> sign of anything other than the paper gasket; should I be using the RTV
> gasket gunk as well? Somehow, I've got to get into the block heater and
> replace it as well. At least with the water pump out, I can see in there
> a bit.
>
> Clint

Re: Best method for extracting bolts with broken off heads...
 

Looking at your picture you "might" be able to get PB in the back of the
bolt through where the water pump goes. Also I find that heat from a propane
torch then pb blaster then more heat and again pb helps. The trick is not
to mess up what you've got to grab onto. So try pb, heat and pb first.

JoBo

"Clint" <cneufeld@mysocks.shaw.ca> wrote in message
news:UJCkh.535564$R63.397938@pd7urf1no...
> So I'm elbows-deep in pulling out my radiator and water pump from my '88
> Jeep Comanche (4.0l, if that matters), and as I figured was likely, two
> bolt heads broke off. I've got pictures, if you care to see
> (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
> broken off just under the head, so there's about 1/2" of threaded material
> to grab, assuming that doesn't break off.
>
> What's the best method you've found to deal with these? Do any of them
> work better than others? If I've got to drill a hole in them, how do you
> get the hole started with an uneven surface like the broken off head?
> Center-punch? That'll be fun to get in there with a hammer...
>
> So far, I figure I'm about 3 hours into the job, and I've got all the old
> parts out. The old water pump actually looks like it's in good shaped
> (vanes all there, looking pretty new), but it was leaking. There was no
> sign of anything other than the paper gasket; should I be using the RTV
> gasket gunk as well? Somehow, I've got to get into the block heater and
> replace it as well. At least with the water pump out, I can see in there
> a bit.
>
> Clint

Re: Best method for extracting bolts with broken off heads...
 

"DougW" <post.replies@invalid.address> wrote in message
news:0UCkh.30072$Rj.29056@newsfe19.lga...
> Clint wrote:
> > So I'm elbows-deep in pulling out my radiator and water pump from my
> > '88 Jeep Comanche (4.0l, if that matters), and as I figured was
> > likely, two bolt heads broke off. I've got pictures, if you care to
> > see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
broken off just under the head, so there's about 1/2" of
> > threaded material to grab, assuming that doesn't break off.
>
> ow
>
> > What's the best method you've found to deal with these? Do any of
> > them work better than others? If I've got to drill a hole in them,
> > how do you get the hole started with an uneven surface like the
> > broken off head? Center-punch? That'll be fun to get in there with a
> > hammer...
>
> I hate dealing with stuck bolts, But you might have enough to get
> vice grips on. Hit it with some PB blaster, tap the head with
> a hammer a few times, and try. Sears has extractor sockets that
> have left hand threads and might work. Similar to these
> http://us.st11.yimg.com/us.st.yimg.c...1925_917971002
>
> If they break off flat it's drill time. I use a center punch but
> sometimes a dremmel will be good enough. Just watch you don't
> destroy the threads.
>
> As for the gasket, just make sure it's clean and use the paper gasket.
> Any other stuff in there just sets you up for future leaks.
>
What he said, plus it looks like you have enough metal there to make the end
of the bolt nice and straight with an angle grinder before drilling. If you
do that, I can't overemphasize the importance of drilling into a flat
surface, assuming you can hold the drill straight. My philosophy is to
forget about screw extractors and go straight for the drill and tap. There
is nothing more annoying than a broke off screw extractor. If you mess up
ask your parts counter person about Heli-Coils.

Permatex Hi-Tac is good for water pump paper gaskets. It sticks, but you
can move the gasket if you position it wrong. If you do use something, make
sure, that it says right on the can, that it is for use with ethylene
glycol.

Earle

Re: Best method for extracting bolts with broken off heads...
 

"DougW" <post.replies@invalid.address> wrote in message
news:0UCkh.30072$Rj.29056@newsfe19.lga...
> Clint wrote:
> > So I'm elbows-deep in pulling out my radiator and water pump from my
> > '88 Jeep Comanche (4.0l, if that matters), and as I figured was
> > likely, two bolt heads broke off. I've got pictures, if you care to
> > see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
broken off just under the head, so there's about 1/2" of
> > threaded material to grab, assuming that doesn't break off.
>
> ow
>
> > What's the best method you've found to deal with these? Do any of
> > them work better than others? If I've got to drill a hole in them,
> > how do you get the hole started with an uneven surface like the
> > broken off head? Center-punch? That'll be fun to get in there with a
> > hammer...
>
> I hate dealing with stuck bolts, But you might have enough to get
> vice grips on. Hit it with some PB blaster, tap the head with
> a hammer a few times, and try. Sears has extractor sockets that
> have left hand threads and might work. Similar to these
> http://us.st11.yimg.com/us.st.yimg.c...1925_917971002
>
> If they break off flat it's drill time. I use a center punch but
> sometimes a dremmel will be good enough. Just watch you don't
> destroy the threads.
>
> As for the gasket, just make sure it's clean and use the paper gasket.
> Any other stuff in there just sets you up for future leaks.
>
What he said, plus it looks like you have enough metal there to make the end
of the bolt nice and straight with an angle grinder before drilling. If you
do that, I can't overemphasize the importance of drilling into a flat
surface, assuming you can hold the drill straight. My philosophy is to
forget about screw extractors and go straight for the drill and tap. There
is nothing more annoying than a broke off screw extractor. If you mess up
ask your parts counter person about Heli-Coils.

Permatex Hi-Tac is good for water pump paper gaskets. It sticks, but you
can move the gasket if you position it wrong. If you do use something, make
sure, that it says right on the can, that it is for use with ethylene
glycol.

Earle

Re: Best method for extracting bolts with broken off heads...
 

"DougW" <post.replies@invalid.address> wrote in message
news:0UCkh.30072$Rj.29056@newsfe19.lga...
> Clint wrote:
> > So I'm elbows-deep in pulling out my radiator and water pump from my
> > '88 Jeep Comanche (4.0l, if that matters), and as I figured was
> > likely, two bolt heads broke off. I've got pictures, if you care to
> > see (http://members.shaw.ca/cneufeld/Imag...ck005Small.jpg). They're
broken off just under the head, so there's about 1/2" of
> > threaded material to grab, assuming that doesn't break off.
>
> ow
>
> > What's the best method you've found to deal with these? Do any of
> > them work better than others? If I've got to drill a hole in them,
> > how do you get the hole started with an uneven surface like the
> > broken off head? Center-punch? That'll be fun to get in there with a
> > hammer...
>
> I hate dealing with stuck bolts, But you might have enough to get
> vice grips on. Hit it with some PB blaster, tap the head with
> a hammer a few times, and try. Sears has extractor sockets that
> have left hand threads and might work. Similar to these
> http://us.st11.yimg.com/us.st.yimg.c...1925_917971002
>
> If they break off flat it's drill time. I use a center punch but
> sometimes a dremmel will be good enough. Just watch you don't
> destroy the threads.
>
> As for the gasket, just make sure it's clean and use the paper gasket.
> Any other stuff in there just sets you up for future leaks.
>
What he said, plus it looks like you have enough metal there to make the end
of the bolt nice and straight with an angle grinder before drilling. If you
do that, I can't overemphasize the importance of drilling into a flat
surface, assuming you can hold the drill straight. My philosophy is to
forget about screw extractors and go straight for the drill and tap. There
is nothing more annoying than a broke off screw extractor. If you mess up
ask your parts counter person about Heli-Coils.

Permatex Hi-Tac is good for water pump paper gaskets. It sticks, but you
can move the gasket if you position it wrong. If you do use something, make
sure, that it says right on the can, that it is for use with ethylene
glycol.

Earle