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I was removing the ps cooler in order to do the harmonic balancer and seal replacement and the bolt on the passenger side broke. I drilled thtie center of the bolt and inserted the extractor. Then slowly was tightening up on the extractor and it broke!! Now my question is, can I tweek the mounting flange a little bit and drill and tap a new hole.
I think the best solution would be to drill the whole thing out and helicoil it, but that may be more trouble than it's worth for a bolt that's under very low stress, and nobody really sees or cares too much about. M6 helicoils can be a pain to work with anyway.
If you can bend the mounting tab enough to line it up with some fresh aluminum on the crossmember, drilling and tapping a new hole would work just fine. I made a custom bracket for a shorter power steering cooler to clear turbo intercooler pipes on my car and had no problem drilling new holes in the crossmember and tapping them to M6x1.0.