Thread: HELP! Power Steering Bolt Broke Off in Block

Originally Posted by jpearsall187

I am having great difficulty drilling a hole. The bits keep breaking. Are there any special type of super hard, super sharp drill bits i can use? Also, if I have to end up tapping this hole for a new bolt, what is the next size up that will do the job but the bolt will still fit through the power steering pump? Thanks

Don't remember the bolt size, but for drill bits, titanium coated and cobalt drill bits are the better bits. The cobalt one's are considered better, but can cost you $50 easily. If you do get the cobalts, don't let the small bits get wobbly and break off. You'll have even more fun trying to drill out cobalt with another cobalt drill bit. I usually use some cutting oil with the bits to keep them cool and drill easier.

Another idea of getting this out is if you know someone who welds, they could try welding a nut onto the end of the broke off bolt. Once it cools, back it out going in both directions to free it. This works sometimes, and others it just keeps breaking off and then u have to drill or grind through a weld and then the original broke off bolt. I think grinding the stud flat with the die grinder and drilling it out is still your best bet, but throwing out other ideas. If you do drill it out, I use left hand drill bits once I get most of it drilled out, usually I don't have to do any retapping after that cause it catches the stud and backs it out. I use these: 13 Piece Left-Hand Drill Bit Set When drilling, just have to be patient, don't try forcing it to drill the hole faster, once you break the surface, usually it gets easier to drill. As others said, don't drill too deep. Take measurement from another bolt and tape off on your drill bit for measurement.