Freakin' Bolts

Considering that bolt lived in oil I don't think any more oil would help. It's gonna look like your delivering a baby before you can start drilling.

Good luck and don't forget the ice chips.

 

Finish getting the side cover off if you haven't already. Put shop towel , plastic, and use you "favorite" method of removing rest of the bolt. May even use a small magnet to pick up small filling after you have drilled, which I assume you will be doing. You were lucky with the heat and the fuel pump right there.

 

Magnets and grease.

 

You didn't say whether you snapped the bolt during tightening it, or trying to remove it. If during tightening it may have bottomed out which will make extraction more difficult.

Get a few sizes of left twist drill bits, and matching extractors. The bits turn counter clockwise and sometimes the bolt will come on out as the drill bit bites in.

Drill the hole as close to center as you can and use a good quality extractor, but you want to be careful not to break the hardened steel extractor off in the hole. That is a nightmare to remove, been there, done that.

 

Is there any way to weld a 7/16 " or 1/2" hex head nut on that stud ? . That would be a sure fire way of removing it before drilling , with No chips or plastic , IMHO.

 

might need to make some sort of offering to the jeep gods
just to help move things along

 

There is a fair chance that without tension on it, it may spin right out with a left hand bit.

If not, I usually just center punch the stub, then use progressively larger drills until the threads peel out.

Eze-Outs are the spawn of satan. They only come "out" when it's "easy."

 

Thats one of the few bolts I have never broken off myself. I use a vacuum cleaner as close as I can to where I am drilling to catch the shavings. I try not to run high rpm's on the drill, usually in the 500-600 rpm range.
Good luck!
-Donny

 

There are some good ideas presented in Youtube videos for removing a broken bolt that is recessed.

"Ese-Outs" are not the only type of bolt extractors, there are better ones. Do a search on it, I watched a review of several types that was informative.

 

You can weld a washer on that bolt then use a large nut, say one for a 5/8" bolt. The weld will not stick to the cast iron. Use a 5/16" washer because they fit tightly on a 3/8" bolt (or 1/4" washer for a 5/16" bolt).

I snapped the bolt off that holds the exhaust pipe to the manifold trying to take it apart. I should have heated it before removing but I was in a rush. Anyways, it was sunken in like this. Took several attempts and lots of heating, but I got the stubborn thing out. I hate drilling. I save that as a last resort.

 

Regardless of method used, remove any item blocking clear access to the broken bolt. Fender and fuel pump if not already done. If drilling is required, this will help mitigate a miss drill/ further damage.

 

Don,
I'm not sure of the specific measurements But you could take your other cover bolt to a local Hardware store. Try for a #5 grade or higher.

 

Im sure its just tapered for ease of assembly. Its a shot in the dark to get it threaded at the other end of the lifter gallery