Toy-SkiTzo

i tried to pull my transfer case today so i could put in my crawler. one of the six bolts that hold the transfer to the tranny broke and i thought no big deal i deal with that later but it looks like the stub that is left of the bolt a fused to the transmision

any ideas on how to get it free? will using heat hurt the aluminum?

cant use a extractor because of location

thanks

rebult junk

i have used heat on alum with no problem

fastkevman

Can't remember where but I have read numerous times of guys heating a stuck bolt and then touching it with a candle quickly, it seems that the wax will creep into the threads and help lube it for removal.
I have never tried this myself but it doesn't sound like it could hurt so why not try it.
Good Luck

CJM

Heat and extractor.

pepsibluefloat

can you drill it out?

thook

Got pic?

longhungsilver

just be carefull.. aluminum doesnt like heat so not to much

CJM

Drill it out he can, tapping it cannot be done b/c the part is cast. He would need to helicoil it.

thook

Huh? I was asking if he had any pics.

A reverse drill bit...smaller in diameter than the bolt....should work well. You wouldn't have to retap, helicoil, or anything. Once you heat it up, the bit will drill in, grab, and pull it right out.

If there's no room, couldn't you let the tranny/t-case assembly droop a bit? Really... a pic would help, if you have one. Not exactly sure what you're dealing with.

CJM

^ Think he meant my post about heat. This is cast stuff and pretty sturdy, a little heat wont hurt.

Targetnut

first soak it with penetrating oil then use a puch and strike it as though you were driving it into the hole. Don't go crazy but wack it pretty good then leave it soak, and repeat several times soaking it each time.

If there is some left stcking out use a vise grip and try to move it. If you get it to move just go a little then soak it again.

If there is none left sticking out then get an approprate sized extractor and drill the broken bolt with the correct size bit. Be careful to get your hole as square to the work as you can. Then try to work it out If it still won't come out then try heat. Don't heat it too much.

If it still won't come out then you may have to drill the whole thing out and helicoil the hole.

thook

Yeah right. I see now. Nah....a bit of heat won't hurt it as long as no hammers are put to it.

Seriously, though....if the PB Blaster doesn't work (try it first) use some heat. And, IMO, a reverse drill bit. I just think they work better than extractors. But, that's just been my experience. Like he said, keep it square.

pennywize

same thing happened when i was rebuilding a case and going to 4.7's. i broke 2 bolt heads off. it was a major PITA to get the case separated after that, the bolts had corroded to the case. eventually after much pb blaster and prying, the case came apart. one bolt was then only finger tight, came right out. the other wouldnt move. i cut it off flush. drilled, starting with a small bit and working up larger. eventually i had drilled most of it out and using a center punch i punched the sides in and pulled the pieces out with needle nose pliers.
ran a tap to chase the threads and called it good. went together with new bolts and no problems since.
it was frustrating enough dealing with a broken bolt on the bench. i cant imagine working on it under the vehicle.

Toy-SkiTzo

thanks for the replys.

i cant drill it because of the location,i will fit ill keep going with the pb

thats exacly whats happining to me

mt_goat

If nothing else works you could try dropping the cross member and lower the tranny a few inches to give to some room for an extractor. It would really suck if you have to remove the tranny because of a broken bolt but that may be the next step. How's your clutch? might be a good time to put a new one in. Putting in my dual cases was a PITA too, I was kind of sorry I did it at the time.

tc

x2

Well, until I took it on the trail with the low gears!

Bolt = steel
Case = aluminum
Steel+aluminum = galvanic corrosion

Be SURE to put antiseize on all the bolts when you put it back together!

Toy-SkiTzo

i have the entire tranny tcase and crossmember out of the truck. i cant use an ectractor because the way the tranny is shapped

mt_goat

Oh my....that is a problem.

thook

Can you weld or have a buddy that welds? Might tac another bolt on to it.

Toy-SkiTzo

cant beccause it sheered halfway down the hole

that is how i plan on getting it out once i seperate the case from the tranny