Twisted off bolt on diff cover!
03-10-2008 | 04:42 AM
#1
Thread Starter
JK Enthusiast
Joined: Aug 2007
Posts: 145
Likes: 0
From: Rogers, Arkansas (missing Colorado)!
Twisted off bolt on diff cover!
Don't ask how, but I twisted off a bolt on my rear D44 diff cover.
I tried the easy-out route, but it busted off too!
Don't want this to go from bad to worse (already has).
Any suggestions?
I thought about drilling it out and putting in a helicoil insert? Worried about whether there is room for one of these (wall thinkness).
Assume I need a bolt in there or it will leak.
Also planning on putting Riddler or ARB diff cover.
It is the top screw on the cover.
tnx
Blue Mesa
I tried the easy-out route, but it busted off too!
Don't want this to go from bad to worse (already has).
Any suggestions?
I thought about drilling it out and putting in a helicoil insert? Worried about whether there is room for one of these (wall thinkness).
Assume I need a bolt in there or it will leak.
Also planning on putting Riddler or ARB diff cover.
It is the top screw on the cover.
tnx
Blue Mesa
03-10-2008 | 05:13 AM
#3
JK Super Freak
Joined: Dec 2007
Posts: 1,235
Likes: 0
Use a smaller drill bit to drill threw what's left of the bolt. If your lucky the rest of the pieces will just fall out. I've done that successfully a number of times. If it works for you, use a tap to clean up the threads and you should be good to go.
03-10-2008 | 08:16 AM
#6
JK Jedi
Joined: Feb 2008
Posts: 7,213
Likes: 7
From: Georgia
That ease out is gonna booger you up. Find somebody that can TIG weld REAL GOOD. All they need to do is tig a good bolt on what is left of the bolt in the differential housing and back it out. This works well even when the bolt is broken off deep inside the hole. Your welder will TIG weld on the bolt that's broken and build it up, then weld the new bolt on it and back it out. BUT, that ease out ain't gonna help at ALL. It really needs to come out first. Then, when you get it out, throw it and THE REST OF THEM AWAY. They are good for nothing.
03-10-2008 | 08:24 AM
#7
JK Freak
Joined: Oct 2007
Posts: 703
Likes: 0
From: Great Lakes
That ease out is gonna booger you up. Find somebody that can TIG weld REAL GOOD. All they need to do is tig a good bolt on what is left of the bolt in the differential housing and back it out. This works well even when the bolt is broken off deep inside the hole. Your welder will TIG weld on the bolt that's broken and build it up, then weld the new bolt on it and back it out. BUT, that ease out ain't gonna help at ALL. It really needs to come out first. Then, when you get it out, throw it and THE REST OF THEM AWAY. They are good for nothing.
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03-10-2008 | 03:13 PM
#8
JK Super Freak
Joined: Oct 2006
Posts: 1,775
Likes: 1
From: Ga
This is what I do if I can't get a nut welded to it.
03-10-2008 | 05:52 PM
#10
JK Junkie
Joined: Mar 2007
Posts: 3,122
Likes: 0
From: Mount Carmel, PA
Years ago, I busted an easy out off inside of a thermastat bolt. I couldnt get the easy out back out, so I used a small dremel bit to grind it out. It was quicker and easier then smoking drill bits every 10 seconds. once that was out I carefully drilled out the bolt and ended up retapping the hole. It was an aluminum intake and the bolt was really seized up in there.