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Unread 03-01-2012, 05:01 PM   #1
AMCMasterTech
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Broken Bolt removal procedure

In an effort to be less of a lurker/leecher, and more of a seeder/giver/contributor, I've been photo-documenting both diesel TJ builds. Even the most mundane stuff can be interesting, so here goes.

This 2011 CJAA diesel was removed from a new Golf that had sustained a head-on collision. In the process of being crashed, the oil filter/cooler housing was broken-off, with several bolts sheared flush with the engine block.

img00917-20120301-1322.jpg  
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Unread 03-01-2012, 05:02 PM   #2
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I used Blue Point kit 1020 for the drill and tap. The set is rather old-school but works great and saves time. This one has come in handy several times.
img00927-20120301-1330.jpg  
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Unread 03-01-2012, 05:05 PM   #3
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First, I cleaned the area od loose dirt and placed some cleaning cloths in the oil gallery openings.
img00923-20120301-1326.jpg  
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Unread 03-01-2012, 05:44 PM   #4
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Using a center punch, I tagged both bolt shanks as close to center as possible. NOTE: theres a few things "going cheap" will not work - punches/chisels/drifts are worth going expensive with.
img00920-20120301-1324.jpg   img00921-20120301-1324.jpg  
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Unread 03-01-2012, 05:48 PM   #5
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I used the extractor kit drill bit, cordless drill on low speed, and plenty of spray lube as cutting fluid. 125 RPM was plenty fast.
img00925-20120301-1327.jpg   img00924-20120301-1326.jpg  
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Unread 03-01-2012, 05:50 PM   #6
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I then placed the extractor in the drilled hole and tapped gently with a hammer to seat. The hex coupler slid over the extractor.
img00928-20120301-1331.jpg   img00929-20120301-1332.jpg  
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Unread 03-01-2012, 05:53 PM   #7
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Both bolts had thread locker on them, which made for some resistance. But with a little patience, both bolts backed right out.
img00932-20120301-1334.jpg   img00933-20120301-1334.jpg  
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Unread 03-01-2012, 05:56 PM   #8
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I then washed the area gently with carb cleaner, and padded dry. I used a magnet and cloth to get any remaining metal shavings. I used tape to cover the boss until the new part comes in.
img00935-20120301-1335.jpg   img00939-20120301-1343.jpg   img00940-20120301-1404.jpg  
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Unread 03-01-2012, 06:09 PM   #9
Jason
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Good post, but the pics are huge!

And that's a very nice IH, btw.
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Unread 03-01-2012, 06:14 PM   #10
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Sorry bout the pic size....I couldn't edit them any smaller.
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Unread 03-01-2012, 06:34 PM   #11
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Thanks for the compliment. That truck could've just as easily been a J-20, and very nearly was. But I was off-shore at the time and someone else beat me to the Jeep pickup. However, like so many CL deals, the 200 fell in my lap, right place right time. IH made some excellent light line vehicles; very glad to have this one!
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