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Help!

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
So in the process of changing all my front diff bushings, I was on the last one (drivers side) and I snapped the bolt. The good news is that the bolt is out. The bad news is that the bolt snapped right where it goes into the nut. I dunno if the nut is welded in there but it's loose now. I can grab the piece of the bolt left in there through the little access hole in the frame but there's another piece of metal in there with a hole the bolt comes up through. I can't get the nut up through that and out the side hole. I'm really in a bind here. I have no idea how to go about this. I can get a new bolt and a nut for it to bolt it back to the frame but with that extra piece of metal in there, the hole in it isn't big enough to get the old nut out and a new nut in. I dunno what to do.
 

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
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Messages
1,248
Location
New Jersey
Do you have space to drill out the bolt? Maybe start with a much smaller drill bit then the bolt, and then go as large as you can as long as it's smaller (thinner) then the bolt. Then you can just extract it
 

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
The welded nut broke loose too and still on this broken piece of bolt. The nut is what's keeping it from coming up and out. There's no room to get in there and turn the nut or the broken piece of bolt. Welding is not an option. I've gotta find a way to get this out with as little damage to the frame as possible. Then I gotta figure out how to get a new nut in there for the new bolt.
 

freeze

Well-Known Member
Messages
46
Location
New England
Not sure if this is an option, but have you looked into taking the front bumper off and fishing the nut out through the front of the frame rail? I can't remember if its too far away or not.
 

4speedfunk

Well-Known Member
Messages
4,250
Location
Tardville
That's called a "captive nut". The nut itself is loose but, its captured and held in place by a sheet-metal tab. This allows some movement of the nut to get things aligned on the assembly line, and the tab keeps it from spinning (not requiring a wrench on the backside). This a very common problem on old muscle car body mounts...the bolt breaks, (or the tab breaks and allows the nut to spin). Either way, it sucks. You got a few options:

ONE:
Drill it from the bottom up and use an extractor...(like Renegade says: you'll need space to do this). Extractors are a problem within themselves, and I only have a 30% success rate with them. They only work when you are trying to back a bolt out. I'm assuming that your bolt snapped while you were loosening it? If so...a standard RH extractor will probably not work. This is because the threads galled and seized while loosening. So you might want to remove the stub by tightening it in the other direction. I don't know if such a critter exists...but what you need is a "left-hand extractor". This will work just like a normal one but, it will spin the bolt in the opposite direction, up and out thru the top of the captive nut. Pluck the stub out with a magnet...problem solved.

TWO:
Stick a plasma or torch tip into the bolt hole and melt the entire captive nut & broken bolt out of the way. Replace the nut with a new one via the tiny round window, but you'll have to find a way to keep it from spinning. Quick, easy, and ugly!

THREE:
Cut an access hole in the frame, and remove the nut & broken bolt from the side. If you do this you will need to make sure you either leave a big enough hole to get a wrench in there (to hold the new nut)...or you will have to mimic the captive nut idea by making your own new captive nut. The H3 frame is very thin at this point and you can easily cut a window in it with a cut-off wheel.

I do have a fourth idea. Since the bolt is broke right where it enters the nut...it might be easier to continue threading it upward (tightening) and remove it from the top. This will require you to somehow spin the remaining piece up and out of the nut. You'll probably still need a bigger window in the frame. Normally vise grips would be used but, in tight spots like this...I have had great success threading a nut onto the remaining bolt stub, and spot welding it to the stub. This essentially makes it into a "bolt" and you simply thread it up and out with a wrench. This would leave the factory captive nut in place, and all you would have to do is get a new axle mounting bolt, and patch the hole you cut in the frame.

Whatever method...Good luck. I've been there...its a bitch...no easy fix.
 

atvspeed4

Well-Known Member
Messages
1,211
Location
massachusetts
Just drill the bolt out. Use cutting oil and a small bit. As you drill slowly increase size of the bit. I have done this a ton of times and it sucks but it works. Eventually you will have only a tiny bit of material in the threads and you can knock it upwards with a small punch. Body mounts on S10s have this happen all the time
 

SuperBuickGuy

Well-Known Member
Messages
3,403
Location
Woodinville, WA
or 4) weld a nut to the broken end of the bolt and extract.... I know welding may not be in your wheelhouse; but that will be the easiest way to get it out since it does 2 things - 1) gets you something to grip and 2) heats the bolt to break the rust bond.
 

4speedfunk

Well-Known Member
Messages
4,250
Location
Tardville
I'm with ATV but, I think the big issue with drilling it is the space restraints. He'll have to pull the whole axle out of the way to get a drill in there. Plus its in a helluva spot...lying on your back and drilling upward, while trying to get the bit reasonably centered on the broken bolt...and drill it straight...all the while the captive nut and bolt are free to move around inside the frame rail. To say "it will suck hard", would be an understatement.
 

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
Well it's do or die time. I've got the cv out. The end plate off the diff. And I'm ready to tackle this. If I can get my dremel in the access hole on the side of the frame and trim a little off the window the bolt is coming up through, I should be able to slip the captive nut up through it. Get the piece of bolt out and drop the nut back through. I assume I broke the tab for the nut since it's moving free in there. It's my own dumbass fault. The more I was thinking about it last night, I realized I was tightening instead of loosening. I was in a hurry. It was dark, about 40degrees and the gf was bitching about going to the grocery store. I was distracted. Now I'm paying the price.
 

Pappibri

Well-Known Member
Messages
1,611
Location
Cohoctah, MI
Yeah, I agree. When I rush something always happens to make it take longer than it would have if I had just taken my time. Now I check, recheck and slow roll
 

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
Well got it done. Was able to open up the inner hole that the bolt comes up through. Pulled the broken bolt up with the nut on it. Slotted the bolt and used a flathead to spin it out. Dropped the nut back in the hole and got the new bolt in. Pheeeewww. Glad that's over.
 

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
All I have is simple hand tools. I don't gave a garage... All I have is the rock driveway in front of my apartment. Maybe one day I'll have a nice place to work on my truck but for now I just throw my little piece of carpet down and start wrenching. This could've been ugly. I'm glad it wasn't though. haven't drove it yet as I had to make that trip to the grocery store. I'll take it for a spin in the morning and see how the new bushings feel. I did notice some cracking on my upper ball joint boots. Which sucks cause they look good otherwise. I'm hoping I can get the truck through the winter without doing any more major projects. That'll give me a chance to start piecing together the front end rebuild... Thanks for everyones suggestions. Probably kept me from having a heart attack. I was seriously a little worried about this one.
 
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