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Unread 08-16-2011, 04:00 PM   #1
JAdams722
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Broken Bolt removal

Hey everyone! I have an 81 CJ7 that I am working on. While stripping it down, several bolts broke off in various locations. I have tried EZ-Outs, anti corrosion spray, etc... to get them out. Are there any tricks that I am missing? The main problem bolts are the ones where the tailgate hinges bolt to the body. They are broken off in the little blocks that are in there. Is there a way to get the blocks out of the jeep to work on them seperate? Any help would be much appreciated.

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Unread 08-16-2011, 04:31 PM   #2
jeepwhore
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How did they break off? Is there any bolt at all protruding out the hole? Or are they snapped off flush?

The only way to avoid cutting an access hole and removing the capture plates to get the bolts out is to try and weld a nut on the end of the broken bolt (the reason I asked if they broke off flush). If they broke flush with the plate I don't think you have any other option than to cut an access hole.
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Unread 08-16-2011, 04:34 PM   #3
RunAmok
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Ive always found a small cold iron chisel/punch set to be best. Get an aggressive angle on the perpendicular and tap it with a hammer till it starts to loosen. I probably take out two or three bolts every week on our steam boiler system and this way never fails.
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Unread 08-16-2011, 08:05 PM   #4
Ken4444
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One common method is to heat the offending nut and bolt with a torch of some kind, then try to remove it with an ez-out. As Jeepwhore mentioned, another method is to weld a nut onto the broken bolt and then use a wrench to unscrew the bolt. The heat from welding may break the rust bond between the nut and bolt. There are several videos on YouTube that show this method.
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Unread 08-16-2011, 09:20 PM   #5
80cj
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When I broke a roll bar mount bolt, I ground the small protruding bolt stub flat and center punched it. Then I drilled through the bolt and ran a tap in. Worked good and admit that luck was on my side.
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Unread 08-16-2011, 09:43 PM   #6
ymurf
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Weld a nut on the bolt.
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Unread 08-16-2011, 10:35 PM   #7
firewalker909
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I removed a couple of broken bolts the same way 80cj did by drilling out the bolt with a drill bit slightly smaller than the bolt diameter and then tapping out the threads. I was able to save a manifold when a stud snapped off shallow the same way.
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Unread 08-16-2011, 10:37 PM   #8
SBpunk
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Welding is best. If you dont have or cant use a welder, drill out a hole. Big enough to put in a square bit. Hammer that guy in there tight. Heat it up really good then use a ratchet to get it out. Short, sharp tugs until it breaks.
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Unread 08-17-2011, 08:12 AM   #9
JAdams722
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Okay, thanks guys. These are some good ideas. I am sure I will get them out. It is a pain, but it is sadly what you have to expect while working on old Jeeps like this.
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Unread 08-17-2011, 08:15 AM   #10
JAdams722
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Also, just fyi the bolts are broken off flush.
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Unread 08-17-2011, 08:25 AM   #11
DT5150
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if they're flush, you can try to weld a washer on it first, then weld a nut to the washer.
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Unread 08-17-2011, 11:59 AM   #12
bkeese
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If you break an easyout off in the bolt you are done!!!!!!!!

We had several like this, some required cutting a hole and replacing the tapped plate in there. This was because the plates started to spin. I think heat is the best, but that is generally before you break them. I've gotten the routine down for drilling and tapping. Simple and easy. Center punch, drill a hole just smaller than the threads, use a very small punch and colapse the first couple of thread and clean with a tap. Done!
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Unread 08-17-2011, 12:07 PM   #13
360Joules
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I have this very same problem from my pass seat. I have been doing work on my car and have taken the seat in and out several times with impact wrench (probably to high of pressure) and snapped it clean off. It is not corroded or anything, and I was going to try the easy out first, but you are saying if it breaks im screwed?:
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Unread 08-17-2011, 12:28 PM   #14
80cj
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Quote:
Originally Posted by 360Joules View Post
I have this very same problem from my pass seat. I have been doing work on my car and have taken the seat in and out several times with impact wrench (probably to high of pressure) and snapped it clean off. It is not corroded or anything, and I was going to try the easy out first, but you are saying if it breaks im screwed?:
If the bolt broke from over torquing, there is no longer any tension on the threads so an easy out may work well in your case. If you find that after applying a lot of torque on the easy out, the bolt still won't budge, find another way. Easy outs are hardened and once you break one off, it's difficult to remove.
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Unread 08-17-2011, 04:41 PM   #15
narizon
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This wasn't on my CJ,but while installing an E-fan in my Silverado I had a rusted/frozen tight 3/8" plug that wouldn't come out.Room was tight & broke several ez-outs and one very hard square bolt remover.I ended up welding several bolts to the plug till it finally became loose.My trusty 24" offset pipe wrench broke it loose.
Just something to consider.



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