Haalp! Broke my primary bolt off! D'oh!

[poorider]

o.k., stupid stupid grr. Like the title says, bolt broke off in the primary while I was taking it out and I can't get the clutch off now to get in there and remove it. My clutch puller won't go in far enough to engage the threads. I can deal with getting the bolt out of the crank once the clutch is off but I can't come up with a way to remove it.
So......anybody got any ideas how to get this clutch off without wrecking anything?

 

[RMKen]

If you can get bolt with the proper threads as our clutch puller bolt, try tipping your sled on it's side (clutch up) fill the hole with water, put thread tape on the bolt to help seal it and thread your bolt in. That should get it off. Do a search on here for clutch removal as their are other guys that talk of doing it this way. Hope it works.

 

[joshkoltes]

left

id guess try a left hand drill bit? be careful not to hit the threaded sides. maby start with a small one and get a good hole started then try a bigger bit to get a good bite.

 

[rp7x]

busted

x2 on left hand drill bit try like a 5/16 put a lot of preasure on it , good luck

 

[Cumminsnorth]

If you can get bolt with the proper threads as our clutch puller bolt, try tipping your sled on it's side (clutch up) fill the hole with water, put thread tape on the bolt to help seal it and thread your bolt in. That should get it off. Do a search on here for clutch removal as their are other guys that talk of doing it this way. Hope it works.

I've done it this way before but I used oil. If you get a good seal and still can't get it off use a little heat from a heat gun and it should pop off.

 

[785RMK]

id guess try a left hand drill bit? be careful not to hit the threaded sides. maby start with a small one and get a good hole started then try a bigger bit to get a good bite.

Try that after you get the clutch off otherwse that will be on long drill bit. Find a bolt that is long enough with full threads and do what RMKen said, so you don't booger up the end of the crank shaft. By the way, what is this on.

 

[poorider]

it's on an 800 in an iqr chassis
hey guys, I have left handed drill bits, that's how I plan on getting the bolt out once the clutch is off. Problem is it will be next to impossible to drill it out without buggerring up my clutch, that's why I'm trying to get the clutch off. Plus the bit would have to be about 10" long for that to work.
The bolt broke on the skinny part just above the threads, and it twisted off leaving a jagged spiral shaped end. just blindly drilling it probably won't work.
Does anybody have the size and thread pitch handy for the puller threads?

 

[AKSNOWRIDER]

it's on an 800 in an iqr chassis
hey guys, I have left handed drill bits, that's how I plan on getting the bolt out once the clutch is off. Problem is it will be next to impossible to drill it out without buggerring up my clutch, that's why I'm trying to get the clutch off. Plus the bit would have to be about 10" long for that to work.
The bolt broke on the skinny part just above the threads, and it twisted off leaving a jagged spiral shaped end. just blindly drilling it probably won't work.
Does anybody have the size and thread pitch handy for the puller threads?

Can you cut a puller down the amount of the broken bolt and get it to thread?..if not I would try and get a soft drift in on the back of the clutch as close to the crank as you can ..heat the center of the clutch up and whack it off there....other wise its gonna be real hard to get the clutch off with out damaging it....you might be able to make a puller that bolted up to all 6 tower bolts( use at least a 1/2 in plate with gussets on it so it holds the towers straight) and could push off the flat end of the crank..heat the center of the clutch up good and put pressure on the puller a little at a time till it popped off......I doubt you can drill the bolt..it is very hard material..if you get the clutch off, weld a nut to whats left of the bolt and spin it off....

 

[meathooker]

Can you cut a puller down the amount of the broken bolt and get it to thread?..

JET FUEL has done this before and it worked great. PM him if you have more questions.

 

[NINJIN]

it's on an 800 in an iqr chassis
hey guys, I have left handed drill bits, that's how I plan on getting the bolt out once the clutch is off. Problem is it will be next to impossible to drill it out without buggerring up my clutch, that's why I'm trying to get the clutch off. Plus the bit would have to be about 10" long for that to work.
The bolt broke on the skinny part just above the threads, and it twisted off leaving a jagged spiral shaped end. just blindly drilling it probably won't work.
Does anybody have the size and thread pitch handy for the puller threads?

do believe they are 3/4-16 unf had to do this a few times. Get a good grade 8 bolt, tip the sled on the side, teflon tape the threads and use some kind of oil or water does work too. Lookout if it is on there good. They can really come flying off.

 

[brycter]

If you cut a puller make sure it lines up stright with the bolt because i can wedge to the side of the broken one and then you are really messed.
good luck!!!

 

[rmkboxer]

I would try a clutch puller for a xlt, they are shorter, and alot cheaper then the one for the 800 I would think it would work but not sure how much is sticking out of the crank

 

[NINJIN]

I would try a clutch puller for a xlt, they are shorter, and alot cheaper then the one for the 800 I would think it would work but not sure how much is sticking out of the crank

the newer clutches have a reduced diameter so a puller for an xlt won't work. I have tried it

 

[rp7x]

busted

weld a ext on the left hand drill , the bit will unscrew the bolt not drill it out

 

[retiredpop]

Use the hydraulic method. It'll come off. Just make sure the threads are well wrapped with teflon tape. If it still doesn't come off and you are below freezing at night then leave everything in place with as much tension as you can get on the bolt and put the sled outside. It'll be off in the morning for sure.

 

[rmkboxer]

the newer clutches have a reduced diameter so a puller for an xlt won't work. I have tried it

damn, I tried.

 

[Kraven]

o.k., stupid stupid grr. Like the title says, bolt broke off in the primary while I was taking it out and I can't get the clutch off now to get in there and remove it. My clutch puller won't go in far enough to engage the threads. I can deal with getting the bolt out of the crank once the clutch is off but I can't come up with a way to remove it.
So......anybody got any ideas how to get this clutch off without wrecking anything?

Leave the clutch on. Forget about the drill bits and extractors.

Remove your E.C.U. box. and voltage regulator from the sled.

I've removed broken bolts before on old Chevy Monza's (showing my age) where the broken off cylinder head bolt is recessed deep down inside the engine block.

Start with approximately a 10" long bolt 1/2" diameter, tape up the sides, leave only the tip and the bolt head exposed, get out your arc welder, clamp the negative lead to the clutch (yeah, don't prefer that but you can't get @ the crank) clamp the positive to the bolt head, run it in to the hole, then turn on the welder and arc the 10" bolt to the broken stub.

It may take a few tries, but this method DEFINITELY WORKS. Eventually the "weld" will be strong enough to facilitate removal of the broken stub.

Hope this helps.

 

[OnlyPolaris]

it is a 3/4" fine thread bolt.

 

[poorider]

thanks for the replys, I will try to find a 3/4 fine bolt long enough for the task and hydraulic it out, if not I guess my puller is getting a modification.
Kraven I think I'll leave that method as a last resort but thanks for the tip
I'll let everyone know how it went

 

[sledcrazzy]

Hey there POORIDER, the hydraulic trick will work, you can use grease or oil, the grease wont make as big of mess as oil spray when it pops. Forget about sticking a bolt down there attached to a welder, I am a welder by trade and there is all sorts of reasons why that is a VERY bad idea. Once you get the clutch off you should be able to weld a nut on the broken stub by welding on the INSIDE of the nut.

Hope this helps