Help-Get out differential shaft lock bolt

[Westislander]

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When I went to remove the retaining bolt it snapped. I think this is what it looks like, any ideas on how to remove what is left???

 

[dhenderz]

Dude, that really sucks. There is zero chance you will drill the remainder of the bolt out. That is a hardened bolt (I believe grade 10 or 12). Not sure why you were wanting to remove the cross shaft, but I expect you're about to get a lot deeper into the diff than you planned. If I were in your shoes I would use a die grinder and grind thru the end of the cross shaft until you exposed the 'pin' end of the retainer bolt. Then I would rotate the diff and pull the shaft out the other way. That would allow you to pull the c-clips and push the axle shafts out. Then you could pull the carrier bearing caps off (mark them left/right & top/bottom) and don't lose track of the shims. Then you could get the diff carrier out and onto a bench to go after the rest of the bolt. I would expect a little heat from a torch and you could probably twist it out with some needle nose vice grips on the portion remaining.

But that's just my thought. Curious if others have any better/diff ideas.

 

[dhenderz]

Or, here's a better idea. Just buy this kit. Geez....

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[Dougnsalem]

https://www.google.com/search?q=how...ndroid-om-lge&sourceid=chrome-mobile&ie=UTF-8

05:51 AM Sep 4th, 11

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NHBandit
Back in the early 80s there was a recall on the axles used in the Monte Carlo, Malibu, etc cars. I was a service tech at a Pontiac dealer at the time and we saw this ALOT. The trick if you haven't buggered it up yet by trying to drill it is simple. Take a dentist pick or something like that and either magnetise the tip or stick a small magnet to the side of the shaft which will also magnetise the tip and turn it out. In every case I ever ran into there were 1 thread or less remaining on the pin and they came right out. It helps sometimes if you wiggle the pinion shaft as you do it. That tool markw posted looks cool and will surely do the job from the looks of it but I would buy one as a last resort. I probably ran into at least 50 broken bolts doing the axle shaft recalls and never ran into one that didn't turn right out with a magnetised pick. Oh and if you're curious the recall was for axles that had too much end play allowing the C clip to fall out and then the axle to leave the car at the worst possible time. That one cost GM ALOT of money.

I've had to deal with 5 or so broken ones over the years. This is your best answer, off some random Camaro site. If you haven't hacked up the carrier or bolt yet, then it should unscrew like this guy said. There's a bazillion YouTube videos on the Google search also. Try the pick first!

 

[ajd89]

I had one that was broke off but after the threads. I used a long 12 inch drill bit and a ez out. I took the top part out and drilled a hole in it the same size as my 12 inch bit. Then screwed that back in my diff so I wouldn't screw up my threads and used the long drill bit got a hole in the broke off part and used a ez out and it came right out.

 

[Westislander]

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https://www.google.com/search?q=how...ndroid-om-lge&sourceid=chrome-mobile&ie=UTF-8

05:51 AM Sep 4th, 11

You must be registered for see images

NHBandit
Back in the early 80s there was a recall on the axles used in the Monte Carlo, Malibu, etc cars. I was a service tech at a Pontiac dealer at the time and we saw this ALOT. The trick if you haven't buggered it up yet by trying to drill it is simple. Take a dentist pick or something like that and either magnetise the tip or stick a small magnet to the side of the shaft which will also magnetise the tip and turn it out. In every case I ever ran into there were 1 thread or less remaining on the pin and they came right out. It helps sometimes if you wiggle the pinion shaft as you do it. That tool markw posted looks cool and will surely do the job from the looks of it but I would buy one as a last resort. I probably ran into at least 50 broken bolts doing the axle shaft recalls and never ran into one that didn't turn right out with a magnetised pick. Oh and if you're curious the recall was for axles that had too much end play allowing the C clip to fall out and then the axle to leave the car at the worst possible time. That one cost GM

I've had to deal with 5 or so broken ones over the years. This is your best answer, off some random Camaro site. If you haven't hacked up the carrier or bolt yet, then it should unscrew like this guy said. There's a bazillion YouTube videos on the Google search also. Try the pick first!

Doug, great advice, Thank you!!! I was able to pick away at it and it spun right out

 

[Westislander]

I posted this on my build thread... do you think this cross shaft is excessively worn? When checking the rear end initialy the only slop I saw was where this shaft slid into the spiders. It wasn’t much but it was noticeable

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[MrMarty51]

Looking at the wear on the shaft, the holes in the ring gear carrier is probably wobbled out just as bad, not much fix for that other than a new RG carrier.

 

[Dougnsalem]

Looking at the wear on the shaft, the holes in the ring gear carrier is probably wobbled out just as bad, not much fix for that other than a new RG carrier.

This is IMHO- it just depends on what you're doing with the differential. All new bearings, R & P, and seals? It MAY be best to do the carrier, spider gears and cross shaft. I never have, and I've put some pretty nasty looking, sloppy spider gears back in. Basically, they only come into play when you go around corners, so you wont get noise like a hammered ring and pinion would give you. Again, IMHO; that shaft doesn't look that worn. Take it into a differential shop and get their opinion on it. Kinda hard to tell off internet pictures. Anyways, that's cool you were able to get the bolt out. Glad I could help out....

 

[82c10stepside]

I have probably removed a hundred of these over the years. The first thing to do is hose it down with brake cleaner because the gear oil causes a suction on it when you try to remove. If it broke with some thread left you just use a pic to unthread it. If no threads I use a magnet that fits in the hole. Never had to drill one or mutilate the carrier.

 

[ali_c20]

Maybe it's a good "excuse" to buy a limited slip or locking diff