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try drilling next to it
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Posted by Graham [Email] (more from Graham) on Tue, 6 Dec 2005 14:37:25 Share Post by Email
In Reply to: Brake job from hell - frozen rotor screw, techlectic, Tue, 6 Dec 2005 13:56:03
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I'd suggest finding a small (but tough!) bit that will allow you to drill through the bolt parallel to the easy-out and right next to it, instead of trying to through the easy-out. Do this more than once, if there is room. Eventually, that should weaken the bolt enough to remove the easy-out (and the remnants of the bolt, for that matter).

If the bit is small enough, theoretically you won't damage the threads of the bolt hole. (But plan on breaking a few bits in the process). Also keep applying the penetrant and also apply some heat around the bolt hole (not to the bolt itself) to help break loose the bond between the bolt and its hole. Ordinary butane torch can do this.

Also, conventional wisdom says that PB Blaster (available at Wal-Mart, NAPA) works better than Liquid Wrench.

I did the exact same thing as you with a bolt in the aluminum trailing arm on the rear suspension of a Triumph TR-6. Unfortunately, the bolt was so small that I damaged the threads of its hole using the drilling-out process, so I had to use a Helicoil. Fortunately, the bolt was only to hold a rubber bump stop.

Best of luck. Also, I would support federal legislation banning the use of Torx bolts under any circumstances. Saab loves those things ... it's like a plague.

--Graham


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