Thread: HELP! Power Steering Bolt Broke Off in Block

like OH4CompG said, drop the cradle should help out, then if you can get a grinder to the broke bolt smooth it off, hit the bolt center with a center punch, and a dewalt 9 volt drill (or small drill or right angle drill if a regular one wont fit) and a 1/8 drill bit as a starter bit, maybe you can get a back out in there after this, if not get a bit one size smaller than the bolt and drill it, and then tap it out.

put the one bolt that's still good in the pump and measure how far it sticks out, don't drill any deeper than this, you can put tape on the bit as a guide.

So the bolt is broken off jagged inside the hole. It is not a flat surface, so drilling it in the center is probably not possible as the bit always travels toward the edge. Does anyone have any suggestions on how to center it? Also, anyone have a quick run down on how to drop the passenger side of the engine cradle. I think I may have done it once before when I did the rack and pinion, but I forget what's involved. Just trying to plan. Thanks

man that sucks, the only ting i can think of is if you make some kind of jig to hold the bit centered.

maybe trace the back of the pumps bolt holes and drill the holes out of a thick piece of flat stock, bolt the good bolt through the jig and line the other hole up with the broken bolt and try to drill it out.

come to think of it, if you pull the pumps pulley off you could maybe use the pump its self to line up the drill bit.

If the bolt is broke off inside the hole, I say air grinder with a die grinder bit. Use the end of the die grinder bit. For example: 1/4" Air Die Grinder Kit Just try to watch the sides to keep from making a pain to tap, but at least it shouldn't walk and then try drilling it when you get it flat. Done it a couple times, steady hands needed.

Cut the bolt off so its flat.......

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

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.

Yep, left had drill bits work great. Snap on has them also. You can also use a centerdrill to get started. If your drill is leading off, a centerdrill is your best bet, or as stated above use a die grinder with a small bit to grind a center starting point in the end of the broken bolt. A mapgas hand held torch can help as well.

Got it out. Dropped the engine down, used a dremel to flatten the end of the bolt, drilled out the center with left hand drill bits, and then used an easy out to pull it out. However, now that everything is back together, I still have my original problem (in another post) plus my ABS, Check Tire Pressure, and Air Bag lights in the dash are on and won't go off. What could this be?