Snapped a bolt!

Supahone · 03-10-2021, 02:41 PM

Okay I did a bone head move and snapped a bolt while upgrading the plastic coolant jacket to metal. I'm now preparing myself with the arduous task of having to basically remove the front components to give me more space drill and tap the bolt out. Does anyone have any tips on the most efficient way to proceed?[IMG]undefined[/IMG]

ewicky · 03-10-2021, 02:53 PM

Just did this job last night! Well, the coolant flange job. Plastic was disintegrated and leaking. I was definitely thinking "ok don't overtighten" to myself.

You might be able to get a right angle drill in there taking nothing more than the fan out. Good luck!

Broke an aluminum bolt doing the oil cooler side of the OFHG. Turned out the bolt was bottoming out, that's why it broke before it was even snug. Learned my lessen.

Supahone · 03-10-2021, 03:03 PM

Quote:

Originally Posted by ewicky

Just did this job last night! Well, the coolant flange job. Plastic was disintegrated and leaking. I was definitely thinking "ok don't overtighten" to myself.

You might be able to get a right angle drill in there taking nothing more than the fan out. Good luck!

Broke an aluminum bolt doing the oil cooler side of the OFHG. Turned out the bolt was bottoming out, that's why it broke before it was even snug. Learned my lessen.

You have no idea! I was literally saying to myself "Dont break the bolt! Dont break the bolt!" Then I felt the snap. It was like missing a putt for a birdie on a Par 2! I have snubby drill on order due to arrive thursday.

_N54 · 03-10-2021, 05:24 PM

Quote:

Originally Posted by Supahone

You have no idea! I was literally saying to myself "Dont break the bolt! Dont break the bolt!" Then I felt the snap. It was like missing a putt for a birdie on a Par 2! I have snubby drill on order due to arrive thursday.

I would use this or something similar

https://www.harborfreight.com/3-8-ei...7110910f0237bb

and one of these to pull it out

https://www.lowes.com/pd/IRWIN-Extra...ine/1003189120

tcphoto · 03-10-2021, 06:08 PM

Doing the Mickey Mouse mod? I did the same on my E46 while doing the OFHG (longest bolt) and tried to extract it but was unsuccessful. Luckily, it did not leak and I traded it in without a problem.

Supahone · 03-12-2021, 04:38 PM

Had to drill out the 6M bolt drill with a 7m drill bit, to get a clean thread, rethreaded with an 8m bolt.[IMG]undefined[/IMG]

feuer · 03-12-2021, 04:55 PM

Quote:

Originally Posted by Supahone

Had to drill out the 6M bolt drill with a 7m drill bit, to get a clean thread, rethreaded with an 8m bolt.[IMG]undefined[/IMG]

I suggest you use a helicoil to reduce it from 8mm to original 6mm because if this happens again you will have lot bigger hole and bigger issue.

Supahone · 03-12-2021, 07:02 PM

Quote:

Originally Posted by feuer

Quote:

Originally Posted by Supahone

Had to drill out the 6M bolt drill with a 7m drill bit, to get a clean thread, rethreaded with an 8m bolt.[IMG]undefined[/IMG]

I suggest you use a helicoil to reduce it from 8mm to original 6mm because if this happens again you will have lot bigger hole and bigger issue.

Thank you! Thats a great idea. Though hopefully going to a metal inlet will mean I never have to touch that bolt again.

Dave92N54 · 03-13-2021, 01:08 PM

Quote:

Originally Posted by Supahone

Quote:

Originally Posted by feuer

Quote:

Originally Posted by Supahone

Had to drill out the 6M bolt drill with a 7m drill bit, to get a clean thread, rethreaded with an 8m bolt.[IMG]undefined[/IMG]

I suggest you use a helicoil to reduce it from 8mm to original 6mm because if this happens again you will have lot bigger hole and bigger issue.

Thank you! Thats a great idea. Though hopefully going to a metal inlet will mean I never have to touch that bolt again.

Next time you do the OFHG you'll probably rethink that statement...

relative4 · 03-13-2021, 04:04 PM

Absolutely no reason to mess with the mickey mouse when doing the OFHG.

TheMidnightNarwhal · 03-13-2021, 04:48 PM

Quote:

Originally Posted by relative4

Absolutely no reason to mess with the mickey mouse when doing the OFHG.

Hmm yes there is, or else you need to get a E torx wrench. '

And then anyways you can't torque it properly.

Dave92N54 · 03-13-2021, 08:06 PM

Quote:

Originally Posted by TheMidnightNarwhal

Quote:

Originally Posted by relative4

Absolutely no reason to mess with the mickey mouse when doing the OFHG.

Hmm yes there is, or else you need to get a E torx wrench. '

And then anyways you can't torque it properly.

Yup. Unless you have E-torx box wrenches, just like risking a stripped bolt, or don't torque things to spec then you will need to remove the mickey mouse.

relative4 · 03-14-2021, 12:38 AM

Who doesn't have E-torx box ratchets?

Knob · 09-24-2022, 01:21 PM

Quote:

Originally Posted by Supahone

Had to drill out the 6M bolt drill with a 7m drill bit, to get a clean thread, rethreaded with an 8m bolt.[IMG]undefined[/IMG]

Sorry to bring out an old thread, did you remove all the plastic and radiators in the end? Because I´m facing the same problem right now, it felt hard at first and I was almost there, but then it snapped....

Supahone · 09-30-2022, 08:46 AM

Yes if I recall I had to remove the fan shrowd in order to have enough space to get a drill bit in there. Not difficult just need to take your time and go slow and go straight. I suggest getting new and hardened drill bits. And a good tapping kit. The aluminum is very soft so you just want to take your time.

CantSitStill · 10-01-2022, 12:20 PM

You can often pop a nut on top of a bolt like that and weld the inside of the bolt. The heat will then free it up to screw it out.

03-10-2021, 02:41 PM	#1
Supahone Second Lieutenant 80 Rep 215 Posts Drives: 11 550I, 07 335I, Join Date: Oct 2018 Location: MA iTrader: (0)	Snapped a bolt! Okay I did a bone head move and snapped a bolt while upgrading the plastic coolant jacket to metal. I'm now preparing myself with the arduous task of having to basically remove the front components to give me more space drill and tap the bolt out. Does anyone have any tips on the most efficient way to proceed?[IMG]undefined[/IMG] Attached Images
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03-10-2021, 02:53 PM	#2
ewicky Lieutenant 204 Rep 525 Posts Drives: '07 335xi 4D AT Join Date: Jan 2017 Location: Seattle, WA iTrader: (0)	Just did this job last night! Well, the coolant flange job. Plastic was disintegrated and leaking. I was definitely thinking "ok don't overtighten" to myself. You might be able to get a right angle drill in there taking nothing more than the fan out. Good luck! Broke an aluminum bolt doing the oil cooler side of the OFHG. Turned out the bolt was bottoming out, that's why it broke before it was even snug. Learned my lessen.
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03-10-2021, 06:08 PM	#5
tcphoto Brigadier General 3536 Rep 3,047 Posts Drives: E92 335i 6MT Coupe Join Date: Dec 2009 Location: Nashville, TN iTrader: (1)	Doing the Mickey Mouse mod? I did the same on my E46 while doing the OFHG (longest bolt) and tried to extract it but was unsuccessful. Luckily, it did not leak and I traded it in without a problem. __________________
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03-12-2021, 04:38 PM	#6
Supahone Second Lieutenant 80 Rep 215 Posts Drives: 11 550I, 07 335I, Join Date: Oct 2018 Location: MA iTrader: (0)	Had to drill out the 6M bolt drill with a 7m drill bit, to get a clean thread, rethreaded with an 8m bolt.[IMG]undefined[/IMG] Attached Images
	Appreciate 3 feuer4275.50 tcphoto3535.50 Jaronbwall284.50 Quote

03-13-2021, 04:04 PM	#10
relative4 Major 611 Rep 1,272 Posts Drives: '08 335xi E90 MT stage 1+ Join Date: Feb 2019 Location: Denver, CO iTrader: (0)	Absolutely no reason to mess with the mickey mouse when doing the OFHG.
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03-14-2021, 12:38 AM	#13
relative4 Major 611 Rep 1,272 Posts Drives: '08 335xi E90 MT stage 1+ Join Date: Feb 2019 Location: Denver, CO iTrader: (0)	Who doesn't have E-torx box ratchets?
	Appreciate 3 feuer4275.50 Luper5258.50 Jaronbwall284.50 Quote

09-30-2022, 08:46 AM	#15
Supahone Second Lieutenant 80 Rep 215 Posts Drives: 11 550I, 07 335I, Join Date: Oct 2018 Location: MA iTrader: (0)	Yes if I recall I had to remove the fan shrowd in order to have enough space to get a drill bit in there. Not difficult just need to take your time and go slow and go straight. I suggest getting new and hardened drill bits. And a good tapping kit. The aluminum is very soft so you just want to take your time.
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10-01-2022, 12:20 PM	#16
CantSitStill Private First Class 43 Rep 85 Posts Drives: 335i N54 19t FBO Pump + Meth Join Date: Sep 2015 Location: Glasgow iTrader: (0)	You can often pop a nut on top of a bolt like that and weld the inside of the bolt. The heat will then free it up to screw it out.
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