Best way to remove snapped starter bolt???

[John105]

Had a case on my rear caliper and thought no big deal. But indie could not drill it out. Surprising since no issue accessing it. Had to heli coil it. Just was hard to imagine since full access to what was left…hope you can get it resolved

Ps indie tried heat as well

 

[John105]

I want someone with much more experience than myself to comment. You have enough bolt protrusion to put a piece of copper tubing or plastic over it to get to the exact center to carefully drill it out.Start with the largest bit that fits in the tubing.All you want to do is just dimple the bolt for a exact center.Pick a smaller very high quality bit with a lube to start drilling, slow and carefully. Work your way up.I feel your pain as I also live in the rust belt.I have in my arsenal,left hand center bits to start and left hand twist drill bits.I have had left hand bits walk fasteners out,hopefully with all the good advice here you find a solution.A good thread chaser,not tap,inspect,clean or replace the bolts.Good luck!

I feel the pain too living where roads are salted. My 10 yo used car came from FLA. That was 2016. 2024 a bolt snaps, one that was fine and that I removed myself in 2018…

 

[ElectroMechanoMan]

If you can get the starter off, you should have plenty of bolt left to either weld a nut on or just heat it up. Tap it a few times with a hammer while hot and carefully try to spin it out with a wrench or vise grips.

 

[Mazomopar]

If the starter is toast, drill thru the ear perpendicular to the bolt with two or three holes stacked up in a line. Then crack or chisel off remaining part to give you some room to wiggle it off.

 

[WesternReach]

Thanks everyone for the replies, I will try them until I get it done.

 

[Exhaustgases]

It is corrosion holding the starter in if all bolts are removed. Give it some good hits to knock it free.

 

[WesternReach]

If the starter is toast, drill thru the ear perpendicular to the bolt with two or three holes stacked up in a line. Then crack or chisel off remaining part to give you some room to wiggle it off.

Thank you for that idea, I just might try that.
Any suggestions for the type of drill bit to use and if I should some type of cutting paste?

 

[Mazomopar]

Thank you for that idea, I just might try that.
Any suggestions for the type of drill bit to use and if I should some type of cutting paste?

Looks like it's about 1/2 inch thick so I would take a punch and punch 3-4 dimples about an eighth of an inch apart. In a line parallel and perpendicular to the bolt. Then grab a good 3/16ths or so bit and drill til you hit the bolt. Now you should have 3 or four interconnected holes like a cut with a saw. Might be enough to free it up. If not, lay a chisel in the opening and whack off a chunk of the remaining ear. Nothing fancy needed, just slower rpm's on the drill, smear little grease on the dimples if you want.

 

[AdmiralYoda]

Give the starter a whack, and get a pry bar in between the starter and the bellhousing and pry the starter off.

You need to get some penetrating oil at the threads right at the bellhousing to try and get the oil to wick into the bellhousing.

Spray a couple times each day, give the bellhousing and back of the bolt a whack with a hammer to try and break the corrosion bond.

Use a good set of vice grips and see if you can loosen the bolt from the back side. If not...heat the bellhousing and try again. If that doesn't make it come loose then heat it again, let it cool, then apply more penetrating lube. Repeat a few times if necessary.

 

[mattd]

Get the starter out first. I would weld a nut to the bolt. No need to worry about it sticking to aluminum.

 

[WesternReach]

Looks like it's about 1/2 inch thick so I would take a punch and punch 3-4 dimples about an eighth of an inch apart. In a line parallel and perpendicular to the bolt. Then grab a good 3/16ths or so bit and drill til you hit the bolt. Now you should have 3 or four interconnected holes like a cut with a saw. Might be enough to free it up. If not, lay a chisel in the opening and whack off a chunk of the remaining ear. Nothing fancy needed, just slower rpm's on the drill, smear little grease on the dimples if you want.

Thank you for the clarification

 

[WesternReach]

Thanks everybody for the replies And tips. I’ll be trying these out as soon as the weather clears