Ideas? For getting a broken tap out
Thread Starter
Instructor
Joined: Aug 2010
Posts: 233
Likes: 18
From: Monrovia Md
Ideas? For getting a broken tap out
I was putting my half shafts back on after changing the u-joints. I decided to run a tap through the holes to clean the threads, and the tap broke off in the differential yoke. I got that "wanna puke feeling".
It broke just slightly under the surface. I am Looking for any ideas on how to attack this.
I am afraid I am about to start a restoration on the rear end as I take the differential out to replace the yoke!
And just to let everyone know, there didn't seem to be anything wrong with the u- joints in the first place , Aaarrrrgh
It broke just slightly under the surface. I am Looking for any ideas on how to attack this.
I am afraid I am about to start a restoration on the rear end as I take the differential out to replace the yoke!
And just to let everyone know, there didn't seem to be anything wrong with the u- joints in the first place , Aaarrrrgh
Race Director
Joined: May 2005
Posts: 10,674
Likes: 122
From: Millington Illinois
St. Jude Donor '08-'09
If it don't work, Punch and a hammer. They break up easily if you can get to it. Then, run a tap through after you get all the pieces out.
Last edited by 63mako; Dec 25, 2012 at 07:38 PM.
Race Director
Joined: Apr 2011
Posts: 11,183
Likes: 3,335
From: North of Toronto - Ontario
Taps are brittle and will shatter. You may need to re-sharpen the punch a few times.
Try hitting it in different places (one side then the other) and from different angles.
The back end of a drill bit also works pretty good, sacrifice a 3/16 and snap the flutes off, grind a bit of a point on and hold it with vice-gribs while you hit it.
Also don't need to hit it super hard, just work away at it trying to catch the edge of the tap flutes and shatter them.
Mooser
Heel & Toe
Joined: Mar 2012
Posts: 21
Likes: 0
Quality taps are hardened, forget drilling it out. Chances are you have a chip jammed in it or flexed it and snapped it. There is a tool made to slide in around a 4 flute tap to help back it out but the cost may be more then just replacing the side yoke. A punch and hammer might work if you can catch the edge of the tap to walk it out, taps are brittle so you might be able to break it but that might end up lodging it in the side yoke forever.
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Burning Brakes
Joined: Nov 2011
Posts: 1,170
Likes: 201
From: Willoughby Ohio
The tool you need is called a tap extractor.If you can find a machine tool supply shop in your area they should have one in stock or be able to order one.Drilling out the tap will require a carbide tool due to the fact that taps
are harder than hs drills.I have also cut out taps with carbide endmills depending on the geometry of the tap.Another option if you have to tear it apart is to edm the tap out.
are harder than hs drills.I have also cut out taps with carbide endmills depending on the geometry of the tap.Another option if you have to tear it apart is to edm the tap out.
Melting Slicks
Joined: Jul 2010
Posts: 2,762
Likes: 820
From: SUFFIELD CT USA 2023 C8 CORVETTE UN-MODIFIED FINALIST
2023 C8 of the Year Finalist - Unmodified
What is your yoke worth. A local machine shop may be able to EDM it out for you but that is not cheap! The tap extractor mentioned above sounds like a solid idea !
Thread Starter
Instructor
Joined: Aug 2010
Posts: 233
Likes: 18
From: Monrovia Md
This forum never fails. I never imagined there was such a tool as a tap extractor. I ordered the extractor. I will soak it in PB blaster until it comes.
If the tool doesn't work I will try to break it out. Way better than taking the diff out!
Thanks to everyone!
If the tool doesn't work I will try to break it out. Way better than taking the diff out!
Thanks to everyone!
Safety Car
Joined: Sep 2012
Posts: 4,688
Likes: 41
From: Palm Harbor, Florida
I like this idea the most, at least to get it done quick, not have to wait for any tools, etc.
Racer
Joined: Aug 2005
Posts: 355
Likes: 18
From: Corona Ca
Whatever you do, please wear safety glasses. Hardened metal, like that used in taps, will flake and send parts up into the air towards your face. Also, be aware that the edge on chipped hardened tool steel, and the flakes from it, are really sharp, so be careful running your fingers or hands around the area of the broken tap.
The tap extractors work pretty well, just go slowly. And if you do have to remove the yoke to get the tap out, that is a better end than further damaging the threads trying to muscle it out.
Good luck,
Tom
The tap extractors work pretty well, just go slowly. And if you do have to remove the yoke to get the tap out, that is a better end than further damaging the threads trying to muscle it out.
Good luck,
Tom
Le Mans Master
Joined: Sep 2004
Posts: 5,116
Likes: 5
From: Livonia MI
I've never broken a tap in place, as really try and be careful. Done my share of tap work though. I found a fluid called "Tap Magic" is by far the best tapping fluid. Dont know what's in this stuff, but magic is right. Has kind of a burn't cinnamon smell that I don't like, but definitely makes tapping a breeze.
Le Mans Master
Joined: Oct 2010
Posts: 6,937
Likes: 848
From: melbourne florida
2023 C3 of the Year Finalist - Modified
The tool you need is called a tap extractor.If you can find a machine tool supply shop in your area they should have one in stock or be able to order one.Drilling out the tap will require a carbide tool due to the fact that taps
are harder than hs drills.I have also cut out taps with carbide endmills depending on the geometry of the tap.Another option if you have to tear it apart is to edm the tap out.
are harder than hs drills.I have also cut out taps with carbide endmills depending on the geometry of the tap.Another option if you have to tear it apart is to edm the tap out.
Team Owner
Joined: Jan 2006
Posts: 37,637
Likes: 3,118
From: Crossville TN
Tap extractors are about $10. And, if you take care of them, they will be around for many broken tap repairs.
Right tool for the right job....
P.S. If you bugger up those threads, how much will a new yoke set you back?
Right tool for the right job....
P.S. If you bugger up those threads, how much will a new yoke set you back?
Drifting
Joined: Mar 2009
Posts: 1,253
Likes: 4
From: East Wenatchee (2hours from n e where) WA
Try a tap extracter first, use a small magnet and compressed air and pen oil flood to remove chips and chunks of tap. What ever jamed the tap will probly stop the tap extracter from working. oil and a tap with a ***** punch or very small chisel might help get it to turn. Still stuck? Carefully Start busting it out with the p punch or chisel, a little piece at a time. if it loosens try the extracter again. If not keep bustin it out carefull to minimise damage to threads. use a bench grinder to shape the chisels as nessary. You might need a few punches and chisels to get it done. I have used pin punches with a chisel ground in to the end, it helps protect the threads. good luck!
Drifting
Joined: Jun 2010
Posts: 1,781
Likes: 15
From: Oxford Ohio
Punch and a hammer. They break up easily if you can get to it. Then, run a tap through after you get all the pieces out.[/QUOTE]
There are 2, 3, and 4 flute tap extractors on the old tool truck. Since I bought a full set I've never broken another one.
There are 2, 3, and 4 flute tap extractors on the old tool truck. Since I bought a full set I've never broken another one.
Team Owner
Joined: Jan 2006
Posts: 37,637
Likes: 3,118
From: Crossville TN
The broken tap was jambed going IN; the tap extractor will be winding the broken piece OUT. Unless it was already jambed, then you kept on turning it in tighter until it broke, it will back out OK.