Broken Bolt removal - JeepForum.com

Reply
 
LinkBack Thread Tools
post #1 of 17 Old 08-16-2011, 04:00 PM Thread Starter
JAdams722
Registered User
1998 XJ Cherokee 
 
Join Date: Apr 2011
Location: Fargo
Posts: 28
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.

JAdams722 is offline  
Sponsored Links
Advertisement
 
post #2 of 17 Old 08-16-2011, 04:31 PM
jeepwhore
Registered User
1984 CJ7 
 
Join Date: Jun 2006
Location: Kamloops
Posts: 3,962
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.

'84 CJ-7: Yota axles (spartan locked front, e-locked rear) 4" BDS, 1" Daystar & 3/8" shackle lifts, 35" X-Terrains on steelies, YJ Tub & family roll bar, heater blower upgrade, 4.2L w/MC2100 & Team Rush, Warn 8274. Rebuilt 4.2/4.0 hybrid, AX15 and twin sticks/clocking ring waiting to go in.

The advertised position for a topless, dirty jeep girl has been filled......by my wife. Thanks to all that applied.
<------------and yes, that is her.
:-D
jeepwhore is offline  
post #3 of 17 Old 08-16-2011, 04:34 PM
RunAmok
Registered User
1980 CJ5 
 
Join Date: Sep 2010
Location: Dover
Posts: 52
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.
RunAmok is offline  
post #4 of 17 Old 08-16-2011, 08:05 PM
Ken4444
Corripe Cervisiam
 
Ken4444's Avatar
1985 CJ7 
 
Join Date: Oct 2005
Posts: 6,247
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.

"I give you a republic, if you can keep it." - Benjamin Franklin
Ken4444 is offline  
post #5 of 17 Old 08-16-2011, 09:20 PM
80cj
Web Wheeler
 
80cj's Avatar
1980 CJ5 
 
Join Date: May 2002
Location: Hawaii
Posts: 6,270
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.
80cj is offline  
post #6 of 17 Old 08-16-2011, 09:43 PM
ymurf
Registered User
1979 CJ7 
 
Join Date: Apr 2011
Location: Steelville
Posts: 742
Weld a nut on the bolt.
ymurf is offline  
post #7 of 17 Old 08-16-2011, 10:35 PM
firewalker909
OK, one more.
 
firewalker909's Avatar
1973 CJ5 
 
Join Date: Jan 2011
Location: Yucaipa
Posts: 408
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.
firewalker909 is offline  
post #8 of 17 Old 08-16-2011, 10:37 PM
SBpunk
Registered User
2004 WJ 
 
Join Date: May 2011
Location: Enid
Posts: 464
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.
SBpunk is offline  
post #9 of 17 Old 08-17-2011, 08:12 AM Thread Starter
JAdams722
Registered User
1998 XJ Cherokee 
 
Join Date: Apr 2011
Location: Fargo
Posts: 28
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.
JAdams722 is offline  
post #10 of 17 Old 08-17-2011, 08:15 AM Thread Starter
JAdams722
Registered User
1998 XJ Cherokee 
 
Join Date: Apr 2011
Location: Fargo
Posts: 28
Also, just fyi the bolts are broken off flush.
JAdams722 is offline  
post #11 of 17 Old 08-17-2011, 08:25 AM
DT5150
Registered User
1983 CJ7 
 
Join Date: Jun 2007
Location: Lakes Region, NH
Posts: 1,494
if they're flush, you can try to weld a washer on it first, then weld a nut to the washer.

SOLD! 83 CJ-7. TBI Small Block Chevy 350/TH350/D300, Scout II Dana 44 front, CJ Dana 44 rear. 4" BDS Lift with 35's. Currently Jeepless.
DT5150 is offline  
post #12 of 17 Old 08-17-2011, 11:59 AM
bkeese
Registered User
1949 CJ3A 
 
Join Date: Nov 2010
Location: Clarksville
Posts: 595
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!

1985 CJ7 - total customization underway, Sublime green and Plum crazy purple, Ford 9", 258 w/ Holley 475
1985,93 CJ7,YJ - L98 TPI Vette motor, Atlas twin stick, Dana 60s front and rear, Arbs, 39.5 Swampers
bkeese is offline  
post #13 of 17 Old 08-17-2011, 12:07 PM
360Joules
Registered User
2009 JK Wrangler 
 
Join Date: Jul 2011
Location: Hicksville
Posts: 1
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?:
360Joules is offline  
post #14 of 17 Old 08-17-2011, 12:28 PM
80cj
Web Wheeler
 
80cj's Avatar
1980 CJ5 
 
Join Date: May 2002
Location: Hawaii
Posts: 6,270
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.
80cj is offline  
post #15 of 17 Old 08-17-2011, 04:41 PM
narizon
Registered User
1982 CJ7 
 
Join Date: Aug 2011
Location: Hollister
Posts: 15
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.



narizon is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.



Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Jeep Forums Replies Last Post
broken bolt BigPapaCJ Jeep CJ Forum 4 08-24-2010 01:12 PM
broken bolt removal BlueFalcon Jeep CJ Forum 5 09-29-2009 07:34 AM
Broken oil pan bolt dustbag Jeep CJ Forum 4 04-21-2009 05:00 PM
Broken oil pan bolt dustbag Jeep CJ Forum 0 04-21-2009 05:35 AM
Broken Bolt HELP.. ChrisG1964 Jeep CJ Forum 10 07-05-2006 08:13 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome