Power Steering Cooler Bolts Broken
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2nd Gear
Joined: Sep 2024
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Power Steering Cooler Bolts Broken
Hey all, I’m replacing the harmonic damper on my 03 Z06 and in removing the power steering cooler, both bolts broke off flush. I am having a hell of a time getting them out.
Thinking about drilling new holes 1/2” to one side, and maybe 1/4” below. Has anyone else here had to deal with this? Any other suggestions?
Thinking about drilling new holes 1/2” to one side, and maybe 1/4” below. Has anyone else here had to deal with this? Any other suggestions?
No Hostility Be Happy
Joined: Aug 2018
Posts: 10,082
Likes: 7,398
From: South Hill Wa
2022 C5 of the Year Finalist - Modified
2021 C5 of the Year Finalist - Modified
Mig weld nuts to them. Wrench them out hot. They will come right out.
If no welder take a torch to them and start drilling them while they are hot and the will likely break free. Using like a 3/16 bit. Iirc those holes are not blind.
If no welder take a torch to them and start drilling them while they are hot and the will likely break free. Using like a 3/16 bit. Iirc those holes are not blind.
Running Guns & Moonshine
Joined: Aug 2001
Posts: 12,672
Likes: 7,304
From: CT
Listen to the man.
His idea is best if you can get to the bolt heads with a welder.
Another option is to pull the accessory bracket itself from the car with the pump. Once out you can pull the pump off and eject the bolts.
If you happen to still have the factory plastic pulley on the pump which we all hate, just crack that thing off for easy access and replace with a $25 LS2 metal PS pulley.
His idea is best if you can get to the bolt heads with a welder.
Another option is to pull the accessory bracket itself from the car with the pump. Once out you can pull the pump off and eject the bolts.
If you happen to still have the factory plastic pulley on the pump which we all hate, just crack that thing off for easy access and replace with a $25 LS2 metal PS pulley.
Tech Contributor
Joined: Jan 2007
Posts: 19,472
Likes: 1,171
From: Dyer, IN
Listen to the man.
His idea is best if you can get to the bolt heads with a welder.
Another option is to pull the accessory bracket itself from the car with the pump. Once out you can pull the pump off and eject the bolts.
If you happen to still have the factory plastic pulley on the pump which we all hate, just crack that thing off for easy access and replace with a $25 LS2 metal PS pulley.
His idea is best if you can get to the bolt heads with a welder.
Another option is to pull the accessory bracket itself from the car with the pump. Once out you can pull the pump off and eject the bolts.
If you happen to still have the factory plastic pulley on the pump which we all hate, just crack that thing off for easy access and replace with a $25 LS2 metal PS pulley.
No Hostility Be Happy
Joined: Aug 2018
Posts: 10,082
Likes: 7,398
From: South Hill Wa
2022 C5 of the Year Finalist - Modified
2021 C5 of the Year Finalist - Modified
lol tusc, we've all been there.
anyways, it took a minute but I was able to look at my front cradle and the bolts do go all the way through the wall of the cradle for the cooler clips. so you can see the threads poking out the other side.
I'm confident that if you take a small bottle torch and heat the broken bolts and then start drilling carefully they will like spin right out of the aluminum. Unless the OPs car is a completely rusty corroded basket case than they may just have to be drilled out and then put in longer bolts and nuts on the back side.
I suppose you could helicoil them but that is more trouble than it's worth IMO.
anyways, it took a minute but I was able to look at my front cradle and the bolts do go all the way through the wall of the cradle for the cooler clips. so you can see the threads poking out the other side.
I'm confident that if you take a small bottle torch and heat the broken bolts and then start drilling carefully they will like spin right out of the aluminum. Unless the OPs car is a completely rusty corroded basket case than they may just have to be drilled out and then put in longer bolts and nuts on the back side.
I suppose you could helicoil them but that is more trouble than it's worth IMO.
