Went to bleed my brakes and broke off the rear passenger outside bleeder inside of the caliper. Then let it soak in some more penetrating fluid and gently tapped in an extractor and promptly broke that off inside as well. Kicking myself for not heating up the area with a torch prior to using the extractor bit, but water under the bridge at this point.

Any other things I could try here, other than buying a new caliper?

 

You might let automotive machine shop have a go at it.

 

at this point i would bite the bullet remove the caliper and take it to a machine shop, you are never going to drill out or remove the hardened steel of that extractor properly. I had to pull the head on one of my GTis for the same thing. I figured the machine work was about 80 bucks, the new head was hundreds

 

I rounded one awhile back in the front. Ended up buying a new set just to get by.

But I gave it to my Dad (mechanic). He somehow got it out and re-tapped it for another size. I've still got it for a backup in the event I do something stupid or need a backup again.

 

If you want to remove the extractor yourself you need something carbide to grind the extractor out. Also if the hole is a through hole you can drive the broken extractor through with a punch, upsize the hole to use a larger extractor. When you are all said and done you’re going to want to make sure you get all foreign material out of the caliper. For something like you were removing you won’t have to heat up the part. What size extractor were you using?

http://www.google.com/products/catal...d=0CEcQ8wIwBA#

 

Thanks guys for the replies. I found a used replacement for 90 shipped on ebay. I'll play around with the caliper once it's out.

 

you found an entire caliper for $90? that seems like a good price.

 

Great new caliper is in just need to bleed the brakes and we're done right?

Nope, found fluid slowly dripping from the front drivers side caliper, checked the bleeder and it was snug. Finally got the bleeder removed by tightening-loosening-soak with pb blaster and out with it came most of the threads from the caliper.

Guess I will be visiting a machine shop after all....

 

Do you by chance have one of the junk calipers lying around? I want one of the stock Brembos for a project please let me know if you do!

 

Wish I saw this earlier.....
If you have a broken tap or extractor, what I've found to be easiest is weld a nut to the broken portion of the item that is sticking out the hole and fill the nut all the way up with your bead, let cool and use a ratchet to pull it out. Just be careful not to tack down onto the surface, in this instance, the caliper.

 

Instead of having the shop re-tap the caliper for a larger bleeder ask them to Time Sert it. You will never have a problem pulling threads out again.