Broke Bolt in Block
Thread Starter
Instructor
Joined: Jun 2011
Posts: 124
Likes: 0
Broke Bolt in Block
i have a 98 vett, Well i had a friend of mine helping me change out my idler pulleys and tensioners.. On the main line it was a breeze but then to the ac line, my buddy is smaller than me so he could get his hands in there good, got the ac tensioner pulley assembly in place put the bolt in and started tightening... that's where it went to ****, he broke the bolt off in my block. So i have two questions, 1. can i just buy the bolt from gm or anywhere else. 2. if anyone on here has changed theirs how did you do it?!?! i just wish i would have done that part myself, surely it felt tight to him, or maybe the bolt being 13 years old just was weak... who knows but nay help would be greatly appreciated!!
Le Mans Master
Joined: Nov 2009
Posts: 6,119
Likes: 156
From: Huntington tx
No pics? If it's broken in the block you need to pull off the hood, remove all of the radiator stuff so you can see and use a drill to drill out the broken bolt. Yes you can get another bolt at any hardware store as long as it's metric so you don't break another bolt or cross thread the existing threads. You should really remove everything you can so you can use your drill and drill it absolutely true and straight. A for sure way to drill it out involves taking a yo-yo/die grinder and make the bolt portion flat by grinding the center of it down, then take a center punch and hammer and make a punch mark dead center in the broken bolt. Then take a small drill bit and drill out the center of the broken bolt. Then you have a choice......drill it big enough for an ease-out, or drill it completely out and then use a tap to clean up the threads.
Thread Starter
Instructor
Joined: Jun 2011
Posts: 124
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Man I tried my best to get a pic of it but it is very tight in there. And yea I'm going to pull the radiator etc to get it done right. I'm sure on e I pull that I'll see some other things that need to be done, goodbye tax refund haha
Advanced
Joined: Mar 2011
Posts: 99
Likes: 1
I've had this problem before. Get yourself a carbide milling bit (double flute) and drill it out with that. They are somewhat brittle so be careful with it. It will cut through a hardened bolt a lot better than a cobalt bit will. They are expensive but worth every penny. After extended drilling sessions with cobalt bits I won't do it any other way.
Once I broke a craftsman easy out off in the hole I drilled and had to drill through the easy out. It was a tedious job but the carbide got me through it.
Once I broke a craftsman easy out off in the hole I drilled and had to drill through the easy out. It was a tedious job but the carbide got me through it.
Thread Starter
Instructor
Joined: Jun 2011
Posts: 124
Likes: 0
I've had this problem before. Get yourself a carbide milling bit (double flute) and drill it out with that. They are somewhat brittle so be careful with it. It will cut through a hardened bolt a lot better than a cobalt bit will. They are expensive but worth every penny. After extended drilling sessions with cobalt bits I won't do it any other way.
Once I broke a craftsman easy out off in the hole I drilled and had to drill through the easy out. It was a tedious job but the carbide got me through it.
Once I broke a craftsman easy out off in the hole I drilled and had to drill through the easy out. It was a tedious job but the carbide got me through it.
Burning Brakes
Joined: Mar 2011
Posts: 1,048
Likes: 5
From: Metairie LA
Dealership guy may not be entirely clueless. Here's the parts diagram. I'm assuming #12 is the tensioner you're dealing with. Doesn't show harware--long shot would be bolt #4:
http://parts.nalleygmc.com/showAssem...&searchString=
http://parts.nalleygmc.com/showAssem...&searchString=
Le Mans Master
Joined: Sep 2003
Posts: 6,276
Likes: 227
From: Farmington CT
Cruise-In VII Veteran
Is anyone going to mention the AC bracket is what BOTH the pulleys bolt to!!!!.........and NOT the block
I'm not going to post how to rig a Sunnen machine and line bore a Dart Aluminum LS block unless I have FIRSTHAND experience doing it.......
I'm not going to post how to rig a Sunnen machine and line bore a Dart Aluminum LS block unless I have FIRSTHAND experience doing it.......
Last edited by SteveDoten; Feb 29, 2012 at 03:12 PM.
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Burning Brakes
Joined: Mar 2011
Posts: 1,048
Likes: 5
From: Metairie LA
OK-here's the compressor mount. STILL doesn't show the bolt he's looking for:
http://parts.nalleygmc.com/showAssem...&searchString=
http://parts.nalleygmc.com/showAssem...&searchString=
Le Mans Master
Joined: Sep 2003
Posts: 6,276
Likes: 227
From: Farmington CT
Cruise-In VII Veteran
I added the pic above....
OPTIONS:
1. remove broken bolt
2. remove/replace bracket
Bracket replacemnt.........I leave the AC compressor in the car on a motor swap and have pulled both top and bottom to drop motor, obviously you do not want to do this, but I 'believe' you can pull the WaterPump and unbolt the AC comp to remove the bracket(one bolt).................by no means is this an easy task
Please post if you need any help
Steve
OPTIONS:
1. remove broken bolt
2. remove/replace bracket
Bracket replacemnt.........I leave the AC compressor in the car on a motor swap and have pulled both top and bottom to drop motor, obviously you do not want to do this, but I 'believe' you can pull the WaterPump and unbolt the AC comp to remove the bracket(one bolt).................by no means is this an easy task
Please post if you need any help
Steve
Drifting
Joined: Feb 2008
Posts: 1,596
Likes: 67
From: Bahama North Carolina
Excellent point!! You really know these cars inside and out!
Thread Starter
Instructor
Joined: Jun 2011
Posts: 124
Likes: 0
Steve i feel like a complete idiot you are 100% right the bolt is broke off in the ac bracket, i used your picture and pointed an arrow to the bolt that im going to need. Also do you think its going to be possible to remove this bolt with out taking the bracket off?
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Le Mans Master
Joined: Sep 2003
Posts: 6,276
Likes: 227
From: Farmington CT
Cruise-In VII Veteran
Don't feel like an idoit, you used the forum just like I have for the past 9 years, I've learned a lot from reading and maintaining my personal Z06's
the bracket is only 30bucks new from GM
have any luck with easyout's?
the bracket is only 30bucks new from GM
have any luck with easyout's?
Thread Starter
Instructor
Joined: Jun 2011
Posts: 124
Likes: 0
If that bracket comes with the bolt I may just do that. And I work for a company that makes specialty carbide tools for Boeing ge power Lockheed Martin etc, and we make a carbide easy out so I'll probably ****** one of those off a Cnc haha! To pull the water pump, and get that bracket off I imagine I will have to remove hood and radiator, correct?
Le Mans Master
Joined: Sep 2003
Posts: 6,276
Likes: 227
From: Farmington CT
Cruise-In VII Veteran
If that bracket comes with the bolt I may just do that. And I work for a company that makes specialty carbide tools for Boeing ge power Lockheed Martin etc, and we make a carbide easy out so I'll probably ****** one of those off a Cnc haha! To pull the water pump, and get that bracket off I imagine I will have to remove hood and radiator, correct?
it would be insane to remove the hood........the only time I've done that is for a motor swap out the top
WP, you may be able to leave in, but you'll notice the Tstat housing/neck to be in the way
try your easy out first
