Messed up bolt extraction..... what are my options??

[VorTekX]

When trying to disconnect an AX-15 from a 4.0, I stripped one of the E-12 bolts on the upper mounting hole. My bolt extractor kit failed to work. I tried using a Dremel to cut off the head and then drill it out, but now I got a bit stuck in the hole and I would like to not damage the bell housing when trying to take it apart. Any ideas on what to do? Are there any specialized drill bits that could help?

 

[Pete M]

well, the good news it that's just a hole in the bellhousing.  the threaded bit is in the engine.  I would try removing everything else and see if I can yank the bellhousing off.   

[VorTekX]

I think ive gotten all the other bolts off, would just rocking it side to side be enough? Don't want to damage the input shaft

[Pete M]

do you own a quality 5-way tool?  if not, you should go get one.  one of the best tools ever (just don't get a cheap one)  I would grind that area flat again (trying to eliminate any burrs you've caused that would hurt the process) and use the 5way as a chisel starting with the far side and work my way around.  meaning you're probably going to need to pry them apart, starting with the thinnest tool, the 5way.

 

you need to make sure that you've gotten all the other bolts, including the inspection cover ones, or this is an exercise in futility.  

[VorTekX]

5 minutes ago, Pete M said:

do you own a quality 5-way tool?  if not, you should go get one.  one of the best tools ever (just don't get a cheap one)  I would grind that area flat again (trying to eliminate any burrs you've caused that would hurt the process) and use the 5way as a chisel starting with the far side and work my way around.  meaning you're probably going to need to pry them apart, starting with the thinnest tool, the 5way.

 

you need to make sure that you've gotten all the other bolts, including the inspection cover ones, or this is an exercise in futility.  

I'll go pick one up next time I'm by home depot

[Pete M]

5 minutes ago, yungupgrade said:

I'll go pick one up next time I'm by home depot

 

it's in the painting section   I wouldn't bother with the more complicated 9-in-1s or whatever silly number they are up to.  you just want a strong flat stiff chisel/prybar/scraper/etc that you can hammer on without fear of it breaking apart in your hand.  this one is 15 bucks and is one of my favorite tools.

 

[cruiser54]

I know you probably don't wanna hear this now, but I'm posting it for anyone who doesn't know.

 

Whenever separating the engine and trans, ALWAYS break those 2 upper bolts loose before any others. 

[AZJeff]

Another tool that might help after the Five-way suggested by Pete M is an indexing pry bar like this one

[Pete M]

also, also, I prefer to hit slowly with my 3lb sledge than swing hard with a regular hammer. 

 

more speed = more chance of something going horribly wrong. 

[jpnjake]

Before you go to using a pry bar or hammer ensure you got all the bolts on the engine plate and engine, some face forward and are easy to miss.

Try grinding the bolt head flat that is stripped out to ensure it isn’t holding things up anymore, then it should just act as a 3rd dowel pin and require extra prying at the top of the trans. once you get it off you should just be able to get the leftover stud off with vice grips and some encouraging words. 

[pizzaman09]

One could also try welding a nut to the stub of the damaged bolt.  The heat should help break free the threads and the nut gives you a great place to stick a wrench on.

[Tex06]

Any luck? 

[VorTekX]

On 8/8/2023 at 8:40 AM, pizzaman09 said:

One could also try welding a nut to the stub of the damaged bolt.  The heat should help break free the threads and the nut gives you a great place to stick a wrench on.

I unfortunatly don't own a welder.

[VorTekX]

3 hours ago, Tex06 said:

Any luck? 

Will be back home tomorrow and will attempt. Don't have much time for the truck as I travel for work.

[jpnjake]

On 8/8/2023 at 8:40 AM, pizzaman09 said:

One could also try welding a nut to the stub of the damaged bolt.  The heat should help break free the threads and the nut gives you a great place to stick a wrench on.

I considered suggesting this, I’d just be worried about melting the aluminum 

[watchamakalit]

5 hours ago, jpnjake said:

I considered suggesting this, I’d just be worried about melting the aluminum 

The aluminum will disapate the heat faster and won't melt. I have seen EXPERIENCED torch users melt steel fasteners out of aluminum housings without damage to the aluminum.

[VorTekX]

Went to home depot and got a 5 in 1. Using that, a crowbar, careful precision with the rotary tool, and a hammer I was able to get it done. Thanks for the help!

[Pete M]

excellent!     now replace the tops bolts with some grade 8 studs and nuts.