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Old 04-09-2009, 02:13 AM   #1
profall
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Member#: 187702
Join Date: Aug 2008
Chapter/Region: South East
Location: All over the place.
Vehicle:
2002 WRX Hybrid
1984 Volvo 242R

Default Broken Steering Rack Bolt, need help.

I was replacing my Steering Rack bushings, and the passenger side went in fine, no problems and took about 5 minutes tops. I go to the drivers side, get the first bolt off no problems really, start working on the second bolt on the bracket and the head just comes right off the bolt.

So, the remainder of the bolt was now stuck inside the frame of the car, so I go and get some Titanium drill bits and an Easy out thinking it'd be quite an easy fix, well I drill a hole and hammer the easy out in there and I am trying with all my might to try and get the bolt to come out and the easy out broke off and it is now inside the hole that I drilled. I cannot drill the easy out now because I do not have a bit or a drill strong enough to get through the metal it is made out of, and I really don't want to drive around with only one bolt holding in my driver side part of my steering rack considering that will bend over the time, not to mention be very unsafe.

I know I am in Prescott, but if I have to go down to the Valley I will. Does anyone have any sort of tools that could get this thing out? I really do not feel like torching it, as the steering lines/brake lines are surrounding the bolt and I don't want to drop the whole steering rack just so I can get to it without torching the lines. Any recommendations on what I should do? I need to drive 2500 miles cross country in about 3 weeks from now.
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Old 04-09-2009, 02:22 AM   #2
racingfish
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Join Date: May 2004
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Location: Goodyear
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1969 LGT
FATURBO

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the boys over at fat or goodspeed is who id contact...
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Old 04-09-2009, 03:43 PM   #3
blkscooby
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Member#: 44422
Join Date: Sep 2003
Chapter/Region: SWIC
Location: Gilbert, AZ
Vehicle:
2005 LGT
OBP

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I had this same problem with my 98 L. You need to go get better drill bits and just keep working at drilling into the easy out and then also try a punch/ chisel. Heat might help also. The easy outs are brittle, albeit hard. You should be able to get that out and try again. It took me 5-6 hours but I was able to get mine out and replace with new bolts.

Oh, I broke 2 bolts.
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Old 04-09-2009, 07:52 PM   #4
profall
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Join Date: Aug 2008
Chapter/Region: South East
Location: All over the place.
Vehicle:
2002 WRX Hybrid
1984 Volvo 242R

Default

Quote:
Originally Posted by blkscooby View Post
I had this same problem with my 98 L. You need to go get better drill bits and just keep working at drilling into the easy out and then also try a punch/ chisel. Heat might help also. The easy outs are brittle, albeit hard. You should be able to get that out and try again. It took me 5-6 hours but I was able to get mine out and replace with new bolts.

Oh, I broke 2 bolts.
Alright, im gonna try that this weekend. I tried drilling it with the Titanium bits and no luck, as well as using a punch and hammer the **** out of it and it did not break off. Im gonna see if I can get a harder bit tomorrow.
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Old 04-09-2009, 08:23 PM   #5
kpluiten
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06 WRBWRXWGN
Now with 100% more Spec-C

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Use very slow drill speed, high force, and plenty of lubricant to cut down on heat. Also,titanium does not equal strong. Look for carbide bits, not the "carbide coated" or "titanium coated" crappers that cost $10, but a real professional style bit. They might be $25 or much more, but they will last and they will cut anything with proper technique. You can also have it sharpened of it breaks or chips. Expensive drill bits are just that, expensive, but like expensive tools, they will last a lifetime. And last thing to remember, do not heat that bit up by drilling like a mad man. This will change the material properties of the bit and it will wear out faster and likely be ruined for any future use. If it turns a color, thats too much heat. Slow speed and lube will prevent this.

In the future, try PB Blaster a couple of times a couple of days before the work and if things get tough, heating the parent material can help A LOT.

Last edited by kpluiten; 04-09-2009 at 08:33 PM.
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