Broken bolt

[jbusch]

Bolt sheared inside my jackshaft. Any ideas on how to remove it? It's pretty flush.

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[dunatyk]

If you can get it in a lathe that’s your best bet. Then use a center drill to start the hole with l. Drill and ez out after that. I would heat the shaft so the bolt releases easier

 

[Betterview]

Lay a nut centered on the broken bolt and carefully weld the center full. Let cool a bit and carefully turn it out.

 

[Coldfinger]

If the bolt isnt rusted in, try using a center punch or edge of a small chisel near the edge and gently hit with hammer to get it to start turning out.

Youtube broken bolt removal for many other ideas.

Since shaft is out, and if the punch doesnt work, and if you are not comfy with the other methods, I bet a machine shop could easily remove it for minimal cost.

 

[jbusch]

If the bolt isnt rusted in, try using a center punch or edge of a small chisel near the edge and gently hit with hammer to get it to start turning out.



Youtube broken bolt removal for many other ideas.



Since shaft is out, and if the punch doesnt work, and if you are not comfy with the other methods, I bet a machine shop could easily remove it for minimal cost.

I was going to call a machine shop today. Having it out makes it easier

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[JMCX]

Reverse twist bits work well in situations like this.

 

[kiliki]

Is this on the clutch side or the chaincase side. It's on the chaincase side and you're using it for a tki belt drive just use a hammer and push it further into the shaft

 

[jbusch]

Is this on the clutch side or the chaincase side. It's on the chaincase side and you're using it for a tki belt drive just use a hammer and push it further into the shaft

I'm running a tki belt drive. I have a good friend who owns a Subaru tuning shop. One of his techs is working on it. Bigger question is why did the bolt snap in the first place. Tom says he hasn't ever seen that happen. Next bolt will be a higher grade. Guess I'm just hard on parts. I should be a parts tester.

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[jim]

Bigger question is why did the bolt snap in the first place.*

Tough to say without detailed pics or the parts. That said, the pic does show corrosion on the bolt failure area combined with shiny spots. This means a lot of it was already cracked before the big failure. How did it fail? Angle on face says torsion or torque...it may have been over torqued during install or a hard hit on the shaft impact the metal and started a crack.

 

[Clark42]

I'm dealing with the same thing right now. '15 jackshaft broken bolt recessed in it, I used an easy out which snapped off inside so a simple thing has turned into a huge pain in the a##. Since it's already out, I'd just take it to a machine shop or someplace with a lathe and have them drill it out

 

[kiliki]

Tki has you install a type of davis blind into the hollow part of the jack shaft and then add the bolt to wedge it as this side has no threads. like i said before you can just push it into the shaft and add a new one as the locking wedges are made to keep it from moving out but will let you push it in.
the big question is why did it break.

 

[jbusch]

Tough to say without detailed pics or the parts. That said, the pic does show corrosion on the bolt failure area combined with shiny spots. This means a lot of it was already cracked before the big failure. How did it fail? Angle on face says torsion or torque...it may have been over torqued during install or a hard hit on the shaft impact the metal and started a crack.

Sled has less than 700 miles on it. I bought with 400 miles and put the tki on it. This season put a silber turbo on it. Personally I think 2 things. First the bolt grade was too low, second I think the rotational force caused the bolt to continue to tighten until the bolt failed. Which comes back to bolt grade.

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[jbusch]

I'm dealing with the same thing right now. '15 jackshaft broken bolt recessed in it, I used an easy out which snapped off inside so a simple thing has turned into a huge pain in the a##. Since it's already out, I'd just take it to a machine shop or someplace with a lathe and have them drill it out

Who's belt drive?

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[richardderkevorkian]

I'm running a tki belt drive. I have a good friend who owns a Subaru tuning shop. One of his techs is working on it. Bigger question is why did the bolt snap in the first place. Tom says he hasn't ever seen that happen. Next bolt will be a higher grade. Guess I'm just hard on parts. I should be a parts tester.

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I broke 3 of those bolts on my 800 mod. Drilled and tapped the shaft to 3/8 and used a grade 8 bolt with red lock tight. Been good for a ~1000 miles

 

[jbusch]

I broke 3 of those bolts on my 800 mod. Drilled and tapped the shaft to 3/8 and used a grade 8 bolt with red lock tight. Been good for a ~1000 miles

I was thinking the same thing. Just a hollow shaft instead of solid. But grade 8 and red locktight

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[jbusch]

Got it out. Drilled and screw extractor.

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[Clark42]

Who's belt drive?

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tki

 

[jbusch]

tki

Gotta love tom though. That guy steps up and helps you fix it right away.

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[Clark42]

Yeah I called in and got to talk to him. I'm sure it's just a freak thing, still annoying none-the-less

 

[jbusch]

Yeah I called in and got to talk to him. I'm sure it's just a freak thing, still annoying none-the-less

Mines back in action. Put in a grade 8 bolt and lots of locktight. I used blue instead of red and will be checking it when I fill oil before each ride. At least until I'm comfortable that its tight.

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