Broken Bolt

[BadJoey]

  Here I go again .I was putting the drive shaft in and from when I painted the rear end the bolt holes had paint in them .Instead of cleaning them out with a tap I was tightening them a little then backing them out and so on . That worked fine for 3 out of 4 but I pushed the one a little to far and opps. I REALLY hate dealing with broken bolts .

So here is my question ? I have never taken the yoke out of a rear end (8 3/4) . It looks like one big nut and pull it out . Is there a million small bearings that are going to fall down inside or is it that simple ?

Next I was going to drill a small hole in the center of the broken bolt , insert a easy out , heat up around it and pray . Usalley this is when the easy out breaks and I make a big mess and end up replacing the part .

Any helpful hints ? It is 1:30 A M and this is bugging the heck out of me .

[Chryco Psycho]

Which carrier do you have , mark the Nut & pinion Before lossening the nut so the torque can be matched back up , if it is a 489 carrier & would really try to get the bolt out Without removing the yolk if it is a 741 or 742 you can remove the yolk , no rollers will fall out
Penetrating oil heat & an easy out is the way I would try to remove it , or weld a nut onto the broken bolt if possible , the heat from welding will help loosen the broken bolt 

[moparmussel]

  i would work on the bolt with rear in place. put small amount of heat to yolk,apply penetrating fluid on it a few times. small drill bit,stright into bolt,size up to about 2/3 bolt size. little more heat and fluid,easy out the rest of the bolt.go slow,stright on the drill.do not rush!

[BS23VOB_FJ5_Faker]

Once you heat the area, touch a small wax candle (birthday candles work well) to the area.  The wax often seeps in and helps loosen things up.  I learned this from an old mechanic.  If you can find a reverse cut drill bit, it will often be enough to back the screw out.  If it doesn't you still have the hole for an easy out.  Careful using the easy out.  I have broken them off in the bolt I was trying to extract and made things worse.

[ksierens]

I think I heard that you should check the drag at the pinion nut with an inch torque wrench and when installing the nut again, tighten it until it reads the same torque setting.  Be careful though, if you tighten it too much you may have to replace the crush sleeve!

I would try to get the bolt out  in the car using an easy-out.

[Alaskan_TA]

Leave the yoke on the car, get a left hand drill bit slightly smaller that the bolt and start drilling it out. The LH bits will nornmally "bite" and spin the broken portion of the bolt out.

Barry

[72hemi]

If you are going to use a lefthand drill get a really good one, so that it will bite in. Not going to be found in your local hardware store more than likely. I know Snap On tool trucks have them, and other specialty tool stores. They were originally made for a Swiss made screw machine that operated with a backward rotation which is why they required left hand drill bits.

[BadJoey]

I went to the local hardware store in search of a left hand drill bit today . All they had was some type of a bit with a easy out build in .It cost$20.00 which I gladly would have done if I thought for a minute it would work . One problem is with the bolt being so small around almost anything I try to use will probably break off inside leaving me really screwed (been down this road many times) Since I have to work M-F I'll probably go for it next Sat . I have several small things to work on, on the week nights and like to save big jobs for the week end .

[Alaskan_TA]

I get my LH bits from NAPA if that helps?

[BadJoey]

 
Bolt is out . It took a couple hours but it's a done deal .I have a knot in my neck because lazy me did not jack the car high enough . First I drilled a small hole all the way through . Next I used a counter clock wise bit although it did not take the bolt out it did break it lose . Next I used a easy out . After the bolt was out I used a tap to clean up the threads in all 4 holes . Used lock tight on the bolts and now the drive shaft is in .    THANKS ALL .

[BS23VOB_FJ5_Faker]

Glad to hear that it had a happy ending.  Nothing quite like the feeling of relief when a broken bolt starts moving again.

[Chryco Psycho]

 

[BadJoey]

Ok something new bothering me . I have changed many universals in the past on other vehicles and there has always been a little nob or something on the yoke to keep the universal caps from sliding out . None on the Challenger so I put the 1/2 lock rings on those caps as well thinking if those caps tried to slip out the rings would stop them when they hit the straps .  Is that correct ? Seems like it has to be and this is just the first time I came across this set up . Thanks .

[Chryco Psycho]

the snap rings go on the caps & hold inside the ears on the yolk