Need help with broken balancer install bolt

[Brian Z.]

Well I've run into a huge problem on my mustang. Was putting the ATI balancer on and the bolt snapped on the install tool (when I went to buy the same kit, out of 6 amazon reviews, 3 reviews gave the kit 1* and said they also snapped the bolt, so maybe it was partly my lack of mechanical skill and part cheap install bolt). About 1/2" of the tip of the bolt broke off in the crank snout, but it was really hard to get to because the threads are about 2" inside the crank. So I bought some long drill bits and bolt extractors and thought I was making good progress. However, it appears that as I was drilling it didn't go straight (I was working blind because of that 2" gap). I've gotten most of the broken piece out and will be able (I think) to get the rest out tonight, but I'm really worried that the threads inside the crank are ruined from where the drill bit didn't go straight. I can still "feel" the thread on the part that I drilled through so it's not completely destroyed.

A buddy has recommended that after I get the last part of the broken piece out that I use a thread chaser, but I have no idea what size to get. Any help is greatly appreciated because I'm beyond upset with myself for screwing this up. I'm not a total newb on mechanical stuff, I did install the KB myself and have wrenched on all of my mustangs, just never had something like this happen.

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[wildcatgoal]

Wonder why you couldn't just run the old stock bolt through there to clean up the threads.

What tool did you use - so we (I) don't have the same fate? I gotta install my ATI soon.

 

[pro 5.0]

M12 x 1.5 Thread is the tap that you need, I find it better to warm up the balancer hub then it slides right on about 3/4 of the way then suck the rest in with a good quality ARP bolt.

 

[Brian Z.]

Wonder why you couldn't just run the old stock bolt through there to clean up the threads.

What tool did you use - so we (I) don't have the same fate? I gotta install my ATI soon.

This is the tool:

https://www.amazon.com/Cal-Van-Tools-35254897-Balancer-Pulley/dp/B00BCQF47K

I borrowed it from a friend, so that's why I had to buy another one to replace it.

 

[jhatley7]

After you get the bolt out, I would use compressed air to clean out the crank then lube the stock bolt and run it in a few times to clean. Go slow and should work well if they aren't too damaged. Then get you a m12 1.5 threaded rod (all thread) and use washer and nut method to pull the balancer back on, rather than push.

 

[dmxxcy]

I ran into the same problem with a different tool. Used a screw driver to slowly turn it out

 

[ProChargerTECH]

I watched on an episode of Gas Monkey garage where they had the same thing happen.

The took another bolt, and ground an area for epoxy to sit in...
Then stuck the bolt in to hit the broken bolt....
Let it cure...

Then it backed right out.

 

[moddirtrcr]

Something else to consider on extracting is left hand drill bits. They are quite nice as you operate your drill in reverse. I've extracted many bolts with Snap On left hand drill bits. Many times the bit itself will back out the broken bolt without even using an extractor.

 

[Tommy V]

Depends on how much bolt is sticking out,i have welded another bolt to the broken bolt,and removed many broken bolts.Fill up the inside of bolt u are welding onto the broken one,sometimes may take 2 or 3 bolts to get good penetration but it works.

 

[Agent_S550]

Once the old portion is out, I would take your old stock bolt, cut a long groove (from head to tip) in it, wire wheel the threads, then run it thru. It will act as a pseudo tap with the ability to take metal shavings with it. If you simply run the bolt in, it will smash any particulates that are in the threads rather than carry them out.

 

[venumous]

Something else to consider on extracting is left hand drill bits. They are quite nice as you operate your drill in reverse. I've extracted many bolts with Snap On left hand drill bits. Many times the bit itself will back out the broken bolt without even using an extractor.

Exactly what I used (along with a CNC machined guide) to back out the crank bolt I snapped off on my Terminator. Came out in like 2 mins.

 

[MyLilPony]

I watched on an episode of Gas Monkey garage where they had the same thing happen.

The took another bolt, and ground an area for epoxy to sit in...
Then stuck the bolt in to hit the broken bolt....
Let it cure...

Then it backed right out.

This, i have done something similar, just use a putty as anything else may get on the treads and cause more issues.


As for re-threading, like most have said, as long as you didnt f'up the main treads you should be fine with running the bolt in an out a few times to get things lined up again. Sucks, sorry :(

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