I need some advice on how to remove a broken bolt. I was replacing the timing belt, components, and water pump on my 2003 evo 8 over the weekend. I had everything back on and went to install the hydraulic tensioner. I hand tightened both bolts, when the one on the right snapped off halfway down the bolt. I have a stud removal tool that I have had a lot of success with which involves drilling a small hole in the stud, inserting the tool, giving it a tap or two with a hammer, then turning it out with the reverse threads. Unfortunately with the engine in the car, I can't get a drill to this stud because the inside of the fender is in the way. I'm not sure how to attack this. I don't have a welder, nor can I weld, and the broken stud is not exposed so the option of tacking a bolt head on is out. My other thought was to remove the front case, but I'm not sure if the bolt goes through the front case and into the block. Other than that, I thought maybe I'd either have to remove more engine mounts and lower the whole engine, or simply remove the engine so I can get this bolt out. I was hoping to post this up here and possibly come upon a better solution.

Thanks in advance for your help guys. Keep up the good work here.

 

I would lower the motor and try that first good luck just be careful because that is a oil passage (galley) behind that bolt that broke be careful and take your time

 

Thanks man. Does anyone know if the thread is in the front case or the engine block? If its only in the block, I can just remove the front case and get a pair of vice grips around the stud. If I were to lower the motor any more I would need a hoist and to remove more motor mounts.

 

I removed the cross member and was able to lower the motor just enough where I can get a long drill bit in there. So tomorrow I'll see if I can pick up a long 1/8" drill bit that will go through the stud fairly easily. If I can do that, then I should be able to extract it from the block, clean out the threads and get this thing back together and running!

 

When you get it out use a torque wrench on the new bolt. I have a quarter in drive torque wrench that is great for getting into tight spaces.

 

Yea I might need to pick up a smaller one. I just have the large 1/2" drive one.

 

I just wanted to post back up with the results of my dilemma. I ended up removing the front case so I could get better access to the bolt. There was maybe 1/16 th" of the bolt protruding from the block and was able to get it out with a pair of pliers and turning it. The bolt wasn't loose. So while I was there I removed the balance shafts, and put new gaskets in everywhere.