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Broken Head Bolt

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Post  marshallgang July 12th 2013, 7:47 am

I was replacing a head gasket on my 1967 Suburban 10 when I broke off a head bolt inside the engine block. The bolt broke off at an angle & when I tried to drill it to use an easy-out the drill bit broke off & became lodged in the bolt hole. I couldn't get either the bit or the bolt out & neither could my local mower repair shop.
It seems like a difficult but not impossible job. Does anyone have any suggestions? This was a really strong running engine & I would hate to have to junk it. Thanks.

marshallgang

Number of posts : 49
Registration date : 2012-09-18

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Post  TKW July 12th 2013, 1:42 pm

hi here is my past experience with this problem working on an old truck i once had. where exactly is the bolt broken at below surface level ? even with surface ? above surface level ? first if the bolt is below the surface and possibly have a couple threads showing you can predrill a hole of a certain size through an other bolt thread that into the hole and use it as a guide to drill a straight hole and the drill that is broken also. then drill the right tap size hole and with a good tap retap the threads. if it is even with the surface or luckly above the surface and you have access to a welder , you can weld a nut to the broken bolt and the heat from that will also help loosen it. i had to do this on two bolts broken removing an exhaust manifold and also of all things a bolt changing a thermostat. its a pain i know but it can be fixed. remember when putting back together anti-seize that stuff is a trouble saver best of luck sure hope this helps /tim

TKW

Number of posts : 108
Registration date : 2011-10-13

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Post  marshallgang July 16th 2013, 7:07 am

The head bolt is broken off down inside the bolt hole. The problem is the drill bit is broken off as well & wedged inside the bolt hole obstructing access. Thanks for the response.

marshallgang

Number of posts : 49
Registration date : 2012-09-18

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Post  TKW July 16th 2013, 9:50 am

couple more thoughts then, what part of the world are you located in ??? have you thought about asking advice from a local speed shop, motorcycle shop, or machine shop ? may have to take your engine off and have some one with a milling machine get it out . if you rather you can PM me also if you like. don't want to give any bad advice here just trying to think of all options i would be thinking of if it was me in the same situation. / tim

TKW

Number of posts : 108
Registration date : 2011-10-13

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Post  marshallgang July 16th 2013, 2:48 pm

I'm located in Canton, Ohio. The Suburban is still at the small engine/ mower shop. He said he had another guy he was going to try to see if he would look at it. So if that doesn't pan out I'll call some machine shops in the area. Thanks for the suggestions.

marshallgang

Number of posts : 49
Registration date : 2012-09-18

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