Broken bolt, need ideas

[Notheryote]

I'm doing opg/cs on a 2019 and the bolt that holds the high pressure fuel pump bracket (metal bracket that holds sound isolator over pump) broke on me. I can't pull the valve cover without removing the stupid thing, problem is is that it's in a relatively hard to get area with a drill if I wanted to try and drill it out. I can't grab the exposed part with nearly enough force to try and turn it, it was extremely stubborn coming out and that's why it snapped.

Any ideas how to deal with this?

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[sdiver68]

Heat and locking pliers? Cut a slot in it and turn with screwdriver? Bolt extractor?

 

[Manny231988]

Or drill small hole in the center use bolt extractor

 

[Notheryote]

Heat and locking pliers? Cut a slot in it and turn with screwdriver? Bolt extractor?

Or drill small hole in the center use bolt extractor

Can't fit a drill in there.

 

[ckendri]

Might use a small right angle drill to get to it?? PB Blaster the thing before further extraction?? I’m not sure what kind of room you have in front of it, but it sounds super tight. Not sure you can even fit a right angle drill in.

 

[ckendri]

Attachment like this?

 

[Notheryote]

Might use a small right angle drill to get to it?? PB Blaster the thing before further extraction?? I’m not sure what kind of room you have in front of it, but it sounds super tight. Not sure you can even fit a right angle drill in.

That might be an option, I'll see if I can get that and try it.

 

[lxh89]

Heat and locking pliers? Cut a slot in it and turn with screwdriver? Bolt extractor?

I was thinking the same thing. Propane torch, needle nose vice grips as a first attempt. If that fails to turn without chewing up the screw, get a dremel with cutting wheel, cut a small notch, heat it up again and use a 3/8" ratchet with a flat nose screw driver attachment.

Just make sure you apply the heat around the bolt, not directly to the bolt. Typically they come out like butter unless it was cross-threaded then you're going to be forced to take everything apart and drill it out.

Tony

 

[ckendri]

That one appears to be a driver, but they may have something like it a drill bit can go in. If not, you may be back to a small right angle drill. A Dremel tool with a flexshaft might be another option.

 

[ckendri]

I like LXH89’s idea of a slot with a Dremel, and then a blade in a small ratchet. Heat would be awesome as long as you don’t catch the fuel on fire.

 

[Notheryote]

I like LXH89’s idea of a slot with a Dremel, and then a blade in a small ratchet. Heat would be awesome as long as you don’t catch the fuel on fire.

I wish I had a welder then I'd just weld a nut to the end sticking out and unscrew it that way.

Might have to go pickup a cheap wire feed welder and try and see if I can just attach a nut to it.

 

[ammoman]

I know this is a really old post, but the exact same thing happened to me this weekend on my 2019 Mustang GT! Since no solution was posted, I'll show how I removed mine.

I modified a bi-metal blade on my oscillating saw and put it between the bracket and mounting point on the head. I angled the blade slightly away from the head as to not damage the aluminum. It took a few minutes, but I was eventually able to cut through the bolt. I did mar up the inside lip on the bracket a little, but the aluminum mounting point was perfect.

I'll try to drill out the old bolt and clean the threads. If that doesn't work, I'll drill it out slightly larger and get a longer bolt to go all the way through with a washer and locknut on the backside. That way this won't every happen again! (I searched on the part number, but nothing came up, so I don't think the bracket can be purchased on its own)

FYI - cutting it this way did produce some small sparks. Since it was by the fuel lines, I had a fire extinguisher next to me just in case.

 

[Angrey]

Take any 1/4" drive bit that you want to sacrifice. Weld it onto the exposed broken bolt tip. Use either a socket or wrench the remove it. Throw it in the ocean.

 

[Boz92]

I know this post is old but just throwing this out there same thing happened to me.

 

[Zrussian13]

I know this post is old but just throwing this out there same thing happened to me.

Same thing happened to me when tearing my engine down. Ford goes a little crazy on the lock tite for that bolt.

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