Broken T-Case Speedometer Housing Bolt - UNCLE

[eric4welches]

I Give. I've been hacking away at this issue for quite some time. I (accidentally of coarse) stripped the bolt head off of the speedometer housing bolt on the transfer case. No problem (I said), I'll just hit a center punch, drill a pilot, then easy-out the remains of the bolt stud. As coach Corso would say "Not so fast my friend". I can't seem to make any headway. I just got done trying HomeDepots cobalt drill bits. All I've managed to do is gaped what's left of the top most threads. I don't want to have to buy a $200-$350 transfer case just so I can mount the friggin speedo cable.

This X is going out for parts.

 

[scott.475]

How many threads are exposed? Are you just not able to to get the bits to drill a hole? That isn't a hardened bolt, so it should drill out.

I'm not a machinist at all, but I did just use cobalt bits to drill a broken bolt out of an exhaust manifold flange. On my 2 speed drill, I had to use the slower speed, and get just the right pressure. Because it was a hand drill, on my first couple attempts the bit jumped around some, causing chips in the cutting edge. I sharpened it back up on a bench grinder, and it worked great after that. Cobalt is awesome, but brittle, so I'm sure all the chattering is what caused the chipped edges. I was actually amazed at how well the cobalt worked, as long as it is sharpened.

May be an obvious question, but is there enough thread left to get a needlenose Vice Grip on?

If you have a Dremel, or die grinder, you might consider cutting it off flush, then grinding a little depression in the middle to help keep your bit centered.