As if I didn't have enough crap to worry about, the smaller starter bolt broke inside the block while I was tightening it. Actually, it wasn't even tightening, it had about an 1/8th of an inch left before it was even touching the starter. I'm reusing the 93 starter and bolts on the 94 engine and the longer bolt went it very smooth. This one was pretty tough to turn. Maybe the 93 bolt is longer? Or maybe someone just broke another bolt inside? Although if that was the case, then this one would've probably not reached as far as it did. Anyway, what can I do now? I'm sure the starter won't be safe on just a bolt and I don't know if I have enough threads before the bolt segment to put in another, shorter bolt....
Thanks.

 

Sounds like drill and extract time.

When a bolt does not feel right, the best thing to do is back it out and take a good look (hole and bolt). Run a thread chaser or tap in the hole if needed.

 

Did you take the starter back off and see if any of the bolt it hanging out? Where you can get something on it to grip it and try to back it out. Some heat might help too. If you get it out make sure you tap the whole and clean the threads up.. If there is a broken bolt other than the one you broke, you can try to drill it out or if its way up in the whole just use some washers on it.

 

Thanks for your help guys.
I didn't try to take the starter out, but I'm sure it's not sticking out. It went too far.
I have very little experience removing broken bolts and the experience I have ended up with failure, so if anyone could give me some directions, I'd really appreciate it.
Also, does anyone know the thread size of these bolts?
Thanks again,
Ion


PS. Sean, I am writing you an email back as soon as I'm done typing this.

 

3/8-16 threads. I know what you mean. Drilling and extracting bolts is not a very exact science. You might try a Google search or two. There are more and different extraction devices available now, than there used to be.

 

If you can find one, a left hand drill bit many times zips it right out.. as you drill it...

 

That's true. You can buy these cool little 'carrot' shaped drill bits at most parts stores. They have a nice sharp groove on the side so when you drill counter clockwise it will catch bolt and screw it out. I'll look online for the tool and I will post it so you know what it looks like if I can find it.

Jason

 

if you're going to buy a bolt extractor, buy a quality name, i've bought a set of autozone extractors, each and everyone of them are broken. I'm guessing you swapped a '94 into your '93? it almost sounds like the person who had the engine before you crossthreaded the bolt and thats where it all went bad. good luck.

 

Here is an example of what I was talking about:

http://www.newmantools.com/drillout/how1.htm

And, blueirocz-28 is right. Don't go cheap. You'll end up paying more in the end.

Good luck,
Jason

 

Thanks a lot for the help guys.
The biggest problem I have is that the garage my car is in has no electrical outlets and I've heard the cordless drills aren't powerful enough for something like this.
I'll see if I can get a bolt in there at least partially to get the car back in one piece and started, then when I can move it, hopefully I'll be able to do this. It would be so much easier to do it while the engine is still out of the car though...

 

Really long extension cord.

 

the extractor will more than likely have a handle or else you can put a wrench onthe end of it. if the bolt is stuck enough to break, then a drill ain't gonna work, drills are highspeed/low torque, which sucks for torquing a stuck bolt.

 

An extension cord that long is gonna cost me just as much as a new engine.
This garage is in the middle of nowhere.

Anyway, just ran over there and took out the other bolt. Things aren't looking good. The bolt, as I expected, is broken inside and I *think* there might be a piece of another bolt in, I'm not very sure about that though.

Here's a picture of the broken bolt.

And here's a picture of the top. You can't really tell what's going on in there but I can't see anything shiny, that's for sure... so there might be a piece of a broken bolt in there. I'll try to take out this one somehow and put another one in with a washer or something.
The other piece (if there is one) will probably be harder to remove.

Man, and this was the last bolt before I was going to put the engine in....

 

at least it broke outside of the car, i'd much rather work on it outside the car than lyin on my back under neath it.

 

Find an 18 volt drill with a few batterys to drill it. The only problem with an extractor is the bolt is probally cross threaded and it will be really tight.I would try to find someway to put heat on it. but you dont want to get it red hot. the cast iron will get brittle and weak. This is what I would try to do. find a big extractor Maybey get one from crafstman but I still dont know if it would be strong enought. Drill the whole deep,pound the extractor in it really good. and get a propane torch and heat the area around the bolt untill it gets good and hot but not red wich I dont think a hand held propane torch would do. Then try to take it out. Good Luck


Sean