Serious Explorations Ford Explorer and Ranger Message Board
#1 Resource for Ford Explorer and Ranger Owners - By Enthusiasts, for Enthusiasts.


Ford Explorer Generation Guide

EF Swag Store 2015 Ford Explorer Forums Elite Membership Chat Room My Posts Reviews Explorer Photo Gallery
Go Back   Ford Explorer and Ranger Forums "Serious Explorations" > Ford Explorer Ranger Repair - Troubleshooting - Modifications & Detailing Forums > Elite Explorer 911!

Notices

Elite Explorer 911! 911! is for situations where your truck is currently out of commission and the owner is in a crisis situation. Members will try to answer your questions asap, no time frame is guaranteed. Only Elite Explorers can post new threads in this forum

Removing Broken Easy-Out

Reply
 
Thread Tools
Old 09-15-2007, 09:57 PM   #1
V8BoatBuilder
Transplanted Bostonian
East Brunswick, NJ
 
V8BoatBuilder's Avatar
97 Mountaineer V8 4x4
 
Join Date: Nov 2002
Posts: 3,428

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
(Original Poster)
Removing Broken Easy-Out

(Not sure where to post this, there are too many sub-forums these days.... I digress)

I have a 6mm (small) stainless steel bolt sheared flush into an aluminum block. I tired using an easy-out, but the bolt was jammed harder than I thought and the easy-out snapped off 1/16" below the bolt surface.

Any suggestions on how to drill this mess out now? My plan is to heli-coil.




__________________
-Aaron
Off Road: 97' Mountaineer: V8, 4x4, 4.56s, 4" Superlift, SOA, TrXus 33x12.5 - Under The Knife
Work: 00' Ranger 4cyl 5spd, 02' Ford E250 5.4
On Road: 2006 VW Jetta TDI/6spd DSG. Fill it with diesel, please.
Octopus Yachts, LLC Engineered Marine Electrical Systems
V8BoatBuilder is offline   Reply With Quote
( Join the Elite Explorers )

For only $20 per year you can become an Elite Explorer member. Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose and fix problems yourself, and learn which modifications really work without having to experiment on your own. Elite Explorer members can change the forum "styles" to eliminate most ads, including blue underlined links, and no ads on photos. Other benefits include the ability to store 1000 Private Messages, upload photo attachments directly to your posts and to our Photo Gallery and more. Join the Elite Explorers today.


Old 09-15-2007, 11:20 PM   #2
MountaineerGreen
Towing Moderator
North East Arkansas
 
MountaineerGreen's Avatar
2012 F150 4x4
 
Join Date: Feb 2006
Posts: 7,518

Vehicle Specs

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 5 Post(s)
Do you have access to left handed drill bits?
MountaineerGreen is offline   Reply With Quote
Old 09-15-2007, 11:33 PM   #3
IZwack
Moderator Emeritus
Germantown, MD
 
IZwack's Avatar
1998 Ford Explorer
 
Join Date: Feb 2003
Posts: 21,827

Vehicle Specs

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 1 Post(s)
I would try heating the area (careful though, you dont want to melt that aluminum )




__________________
...how'd the moon get there, how'd the moon get there?
IZwack is offline   Reply With Quote
Old 09-15-2007, 11:35 PM   #4
section525
sextion525
Red Bluff, Ca
 
section525's Avatar
1975 Ford Bronco 4x4
 
Join Date: Feb 2001
Posts: 14,885

Vehicle Specs

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 7 Post(s)
Is it cross-threaded?




__________________
Support the Forum
'13 3.5 Explorer
'08 2.0 Focus
'75 5.0 Bronco
'04 6.0 Super Duty
section525 is offline   Reply With Quote
Old 09-16-2007, 12:47 AM   #5
manaen
Clear Spring, MD
2011 Xterra Pro-4X
 
Join Date: Feb 2007
Posts: 2,709

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
is there enough clearance to tack weld a rod onto the easy out to at least get it removed?

or take a dremel with a cutting blade and cut a nice slot to fit a screwdriver in and get the easy out removed. then use left handed drill bits to get the bolt.




__________________
Rusty...
2001 Mounty 4x4 4.0 SOHC 4.10's 180K miles
Current Mods: replacement Engine, TT, Shackle, AAL, Tranny Cooler, Exhaust, Transgo, Air shocks, ATF Temp & PSI ga., Ext Tranny Filter, UD Pulley, E-Fan, BW EPC, Custom Bumper, Body Lift
manaen is offline   Reply With Quote
Old 09-16-2007, 08:20 AM   #6
MountaineerGreen
Towing Moderator
North East Arkansas
 
MountaineerGreen's Avatar
2012 F150 4x4
 
Join Date: Feb 2006
Posts: 7,518

Vehicle Specs

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 5 Post(s)
I've also heard of using freon to freeze a bolt to remove it, not sure how that works though, or the legality of doing so.
MountaineerGreen is offline   Reply With Quote
Old 09-16-2007, 09:07 AM   #7
V8BoatBuilder
Transplanted Bostonian
East Brunswick, NJ
 
V8BoatBuilder's Avatar
97 Mountaineer V8 4x4
 
Join Date: Nov 2002
Posts: 3,428

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
(Original Poster)
Thanks for the posts, I don't have access to a welder. I've thought of using my propane torch on the area, but it's very close to gaskets/wiring/etc so I'd like to do that as a last resort.

Where would be the best place to purchase left-handed drill bits? Would they even be able to drill out the hardened easy-out?




__________________
-Aaron
Off Road: 97' Mountaineer: V8, 4x4, 4.56s, 4" Superlift, SOA, TrXus 33x12.5 - Under The Knife
Work: 00' Ranger 4cyl 5spd, 02' Ford E250 5.4
On Road: 2006 VW Jetta TDI/6spd DSG. Fill it with diesel, please.
Octopus Yachts, LLC Engineered Marine Electrical Systems
V8BoatBuilder is offline   Reply With Quote
Old 09-16-2007, 11:43 AM   #8
ld50
Oh, the money you`ll blow
British Columbia
 
ld50's Avatar
93 4 dr 4x4 manual XL.
 
Join Date: Apr 2002
Posts: 4,193

Vehicle Specs

Mentioned: 1 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
This heppened to me once, I used a carbide bit to drill it out, then re-tapped it larger, don`t know if that`s an option?




__________________
Jim from BC - My Mugshot


All My Mods And How I did Them
ld50 is offline   Reply With Quote
Old 09-16-2007, 12:56 PM   #9
V8BoatBuilder
Transplanted Bostonian
East Brunswick, NJ
 
V8BoatBuilder's Avatar
97 Mountaineer V8 4x4
 
Join Date: Nov 2002
Posts: 3,428

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
(Original Poster)
The easy out is smaller than the original stainless bolt, so if a carbide bit would drill it out than that's the answer.

Think HD or Lowes or Autozone would have a carbide bit?




__________________
-Aaron
Off Road: 97' Mountaineer: V8, 4x4, 4.56s, 4" Superlift, SOA, TrXus 33x12.5 - Under The Knife
Work: 00' Ranger 4cyl 5spd, 02' Ford E250 5.4
On Road: 2006 VW Jetta TDI/6spd DSG. Fill it with diesel, please.
Octopus Yachts, LLC Engineered Marine Electrical Systems
V8BoatBuilder is offline   Reply With Quote
Old 09-16-2007, 01:52 PM   #10
manaen
Clear Spring, MD
2011 Xterra Pro-4X
 
Join Date: Feb 2007
Posts: 2,709

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
yeah I think I got a set at HD last time, or maybe it was autozone hmmm...




__________________
Rusty...
2001 Mounty 4x4 4.0 SOHC 4.10's 180K miles
Current Mods: replacement Engine, TT, Shackle, AAL, Tranny Cooler, Exhaust, Transgo, Air shocks, ATF Temp & PSI ga., Ext Tranny Filter, UD Pulley, E-Fan, BW EPC, Custom Bumper, Body Lift
manaen is offline   Reply With Quote
Old 10-09-2007, 12:04 AM   #11
Dre
Elite Explorer
Chicago
 
Dre's Avatar
94 Limited
 
Join Date: May 1999
Posts: 4,794

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
did you ever get it out? I've got the same problem now since I snapped one of the transmission pan bolts... I drilled it tonight and will try removing the bolt tomorrow... wan to see what my options are...

thanks,




__________________
Yankee Kustoms
My Gallery
Dre is offline   Reply With Quote
Old 10-09-2007, 01:25 AM   #12
BrooklynBay
Brooklyn, NY
 
BrooklynBay's Avatar
88 89 93 95 96 Aerostars
 
Join Date: Nov 2005
Posts: 47,870

Vehicle Specs

Mentioned: 2 Post(s)
Tagged: 1 Thread(s)
Quoted: 206 Post(s)
A torque wrench is like insurance in this case. It could help prevent over torquing the bolts in the first place. A thread repair kit might be necessary to use if the housing gets damaged in the process of trying to get the old bolt out.
BrooklynBay is online now   Reply With Quote
Old 10-11-2007, 07:56 AM   #13
gijoecam
Village Idiot
Trenton, MI
98 ExSport, '00 F-150
 
Join Date: May 1999
Posts: 8,353

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 5 Post(s)
To get out a broken EZ out, use a hammer and a hardened pin punch. The EZ out will chip right out of there.

-Joe




__________________
-98 Explorer Sport, 4.0 SOHC, K&N drop-in, LEMON in progress!
-'00 F-150, mucho mods

"We need to allow Darwinism take it's course and let the idiots weed themselves out of existance." ~ Rick Horwitz
We must believe in free will we have no choice.
~ Isaac Bashevis Singer
I'm not smart, just a resourceful idiot. ~ Me
gijoecam is offline   Reply With Quote
Old 10-11-2007, 08:57 AM   #14
manaen
Clear Spring, MD
2011 Xterra Pro-4X
 
Join Date: Feb 2007
Posts: 2,709

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
Quote:
Originally Posted by gijoecam View Post
To get out a broken EZ out, use a hammer and a hardened pin punch. The EZ out will chip right out of there.

-Joe
however in this instance he is hammering against aluminum, I'm not sure that would offer the impact he needs without messing up the part even more.


By now I hope he was able to remove it...




__________________
Rusty...
2001 Mounty 4x4 4.0 SOHC 4.10's 180K miles
Current Mods: replacement Engine, TT, Shackle, AAL, Tranny Cooler, Exhaust, Transgo, Air shocks, ATF Temp & PSI ga., Ext Tranny Filter, UD Pulley, E-Fan, BW EPC, Custom Bumper, Body Lift
manaen is offline   Reply With Quote
Old 10-11-2007, 10:46 AM   #15
gijoecam
Village Idiot
Trenton, MI
98 ExSport, '00 F-150
 
Join Date: May 1999
Posts: 8,353

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 5 Post(s)
Quote:
Originally Posted by manaen View Post
however in this instance he is hammering against aluminum, I'm not sure that would offer the impact he needs without messing up the part even more.


By now I hope he was able to remove it...
No, he's hammering against the broken EZ-out (which is hard and relatively brittle) which is lodged in a steel bolt. I've used a pin punch to break EZ outs out of a lot of differrent items, including aluminum. They're brittle enough that they tend to fracture pretty easily.

Also, I forgot to mention it the first time around... A left-handed carbide drill won't help... if anything, it'll drive the EZ-out even further into the bolt. He needs a right handed drill to remove the extractor, then a left handed drill (and/or another EZ-out) to remove the bolt.

-Joe




__________________
-98 Explorer Sport, 4.0 SOHC, K&N drop-in, LEMON in progress!
-'00 F-150, mucho mods

"We need to allow Darwinism take it's course and let the idiots weed themselves out of existance." ~ Rick Horwitz
We must believe in free will we have no choice.
~ Isaac Bashevis Singer
I'm not smart, just a resourceful idiot. ~ Me
gijoecam is offline   Reply With Quote
Old 10-11-2007, 11:06 AM   #16
manaen
Clear Spring, MD
2011 Xterra Pro-4X
 
Join Date: Feb 2007
Posts: 2,709

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
Quote:
Originally Posted by gijoecam View Post
No, he's hammering against the broken EZ-out (which is hard and relatively brittle) which is lodged in a steel bolt. I've used a pin punch to break EZ outs out of a lot of differrent items, including aluminum. They're brittle enough that they tend to fracture pretty easily.


-Joe
Ahhh... Good point, I forgot about the remainder of the bolt lining the hole around the easy out.


The big question is, did he get it out, and it seems V8boatbuilder has gone AWOL




__________________
Rusty...
2001 Mounty 4x4 4.0 SOHC 4.10's 180K miles
Current Mods: replacement Engine, TT, Shackle, AAL, Tranny Cooler, Exhaust, Transgo, Air shocks, ATF Temp & PSI ga., Ext Tranny Filter, UD Pulley, E-Fan, BW EPC, Custom Bumper, Body Lift
manaen is offline   Reply With Quote
Old 10-16-2007, 06:53 PM   #17
V8BoatBuilder
Transplanted Bostonian
East Brunswick, NJ
 
V8BoatBuilder's Avatar
97 Mountaineer V8 4x4
 
Join Date: Nov 2002
Posts: 3,428

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
(Original Poster)
Quote:
Originally Posted by manaen View Post
however in this instance he is hammering against aluminum, I'm not sure that would offer the impact he needs without messing up the part even more.


By now I hope he was able to remove it...

You totally called it. I was away on business travel, and tried again tonight to get the mess out. I started hammering the ez-out down the hole with a small punch, and it was actually working quite well for a while. But, I was a bit over zealous with my hammering and cracked the aluminum ear right of the cylinder head. The bolt's out, but not the way I wanted.

Looks like I'm part shopping now. Anyone have a cylinder head for an 18hp Tohatsu outboard? Be careful out there guys.




__________________
-Aaron
Off Road: 97' Mountaineer: V8, 4x4, 4.56s, 4" Superlift, SOA, TrXus 33x12.5 - Under The Knife
Work: 00' Ranger 4cyl 5spd, 02' Ford E250 5.4
On Road: 2006 VW Jetta TDI/6spd DSG. Fill it with diesel, please.
Octopus Yachts, LLC Engineered Marine Electrical Systems
V8BoatBuilder is offline   Reply With Quote
Old 10-16-2007, 07:05 PM   #18
CDW6212R
Elite Explorer
Knoxville, TN
 
CDW6212R's Avatar
98 Mountaineer A4WD
 
Join Date: Jun 2004
Posts: 13,510

Vehicle Specs

Mentioned: 3 Post(s)
Tagged: 0 Thread(s)
Quoted: 91 Post(s)
Sorry top hear that, I have a pair of DOHC Cobra heads which UPS dropped, one head has a back corner ear broken off. I'd weld it back on, I will with mine. Try that alumaloy, that rod which melts with a propane torch, and adheres like solder.

Aaron, did you receive my message weeks ago, about your BW4406? I am still browsing for a good mileage TOD shifting version. Where did you look for yours? I haven't found anything with under about 90k on it?




__________________
Don
91 Lincoln LSC/SE, 99/93 Explorer Limited 4WD, 98 AWD Mounty with 255/55/18's, big sway bars, and 12.75" x 1.25" rotors. Soon a BW4406, built trans, stereo and interior.
The best thing that could help us all, is the Fair Tax Plan.
Be American, Buy American (Manufacturer)
CDW6212R is offline   Reply With Quote
Old 10-16-2007, 08:44 PM   #19
V8BoatBuilder
Transplanted Bostonian
East Brunswick, NJ
 
V8BoatBuilder's Avatar
97 Mountaineer V8 4x4
 
Join Date: Nov 2002
Posts: 3,428

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
(Original Poster)
Sorry about the PM Don, I'll send you one now.




__________________
-Aaron
Off Road: 97' Mountaineer: V8, 4x4, 4.56s, 4" Superlift, SOA, TrXus 33x12.5 - Under The Knife
Work: 00' Ranger 4cyl 5spd, 02' Ford E250 5.4
On Road: 2006 VW Jetta TDI/6spd DSG. Fill it with diesel, please.
Octopus Yachts, LLC Engineered Marine Electrical Systems
V8BoatBuilder is offline   Reply With Quote
Old 10-17-2007, 10:02 AM   #20
manaen
Clear Spring, MD
2011 Xterra Pro-4X
 
Join Date: Feb 2007
Posts: 2,709

Vehicle Specs

Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 2 Post(s)
I would take it to a welding shop and have them weld it back on, a good welder can do wonders with aluminum. As long as the part can be cleaned properly.




__________________
Rusty...
2001 Mounty 4x4 4.0 SOHC 4.10's 180K miles
Current Mods: replacement Engine, TT, Shackle, AAL, Tranny Cooler, Exhaust, Transgo, Air shocks, ATF Temp & PSI ga., Ext Tranny Filter, UD Pulley, E-Fan, BW EPC, Custom Bumper, Body Lift
manaen is offline   Reply With Quote
Reply



Suggest this thread to friends:



Join the "Elite Explorers" Today!



Search Explorer Forum


Top of Page

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -5. The time now is 02:59 AM.



US Flag
We Support Our Troops!

Explore the site!


Copyright 2014 - 1996 Rick Horwitz Photography



Ford Motor Company is not involved in the management of this site in any way.



All tips on this site are for use at your own risk and discretion.

Modifying the suspension on any vehicle will cause changes to its handling characteristics.



Vendor Tools vBulletin Plugins by Drive Thru Online, Inc.