Rep Power: 0

hi members,

been working on my 05' ex special edition trying to replace drivers side front lower control arm and as I was trying to loosen the rear bolt it snapped off clean about 1/2" give or take inside the welded nut on the backside of the bolt mount. got the rest of the bolt out but theres about 1/2 inch of it stuck inside the welded nut thats on the subframe. I need help in finding a solution to drill it out and extract the broken piece out, however, i have clearance issues cause i can't fit a drill in front of the mounting bracket because of the strut but i did pick up a 12' drill bit from harbor freight to drill a pilot hole but do not think its for true metal. I also got an extractor set from there as well but the bits are rather short to back out the bolt from the front of bracket. It's a tight fit. and unsure how easy it would be turning the extractor by hand or what tool to use. The extractor bits have square bottoms and would fit in a drill chuck but not a 12" magnetic bit extension snugly that I also have. The only wrenches that fit the extractor bits are rather smaller and i am not sure they have the tourque to back out the bolt. I was thinking of picking up a right angle drill for this also to help things along. Please if someone could help me as I only have 2 decently warm days to finish the repair till the temps plunge and we get snow and I'm trying to not mess up the threads inside the welded subframe nut and have to change out the subframe. I don't even wanna know what a shop will charge. Thanks everyone.

 
Rep Power: 223

You could try using a flathead screwdriver and a hammer. As long as you can get to it hit the proper side to spin the bolt the correct way.

Another option if it comes to it, cut the weld nut off the subframe then replace afterwards. Use a lock nut, double nut, or weld another back on.

 
Rep Power: 0

I also forgot to mention that the bolt i believe snapped inside the control arm. I think we cut the backside of the bolt thats flush with the rear bracket so the little piece of bolt that is stuck inside is flush with the bracket.

 
Rep Power: 223

Is the control arm still in the way? Those bolts like to seize inside the metal sleeve of the control arm bushing. I usually make two cuts on the bushing all the way through, one on top of the control arm and one below. This allows everything to come out except the little bit of bolt still in the threads. I then have more work to get it out though.

 
Rep Power: 0

No, the control arm is out. Just a 1/2” piece left in the welded but on the subframe on the rear bracket. We cut in between the bushing and the bracket and that where I messed up.

 
Rep Power: 223

You could try drilling it out from underneath. Stick the drill bit through the bottom bolt hold first. May be able to get a bolt extract set that's long enough to go through the bottom bolt hole too.

Or cut the weld nut off as previously suggested.

 
Rep Power: 0

I cut off like 99% of the elf but downward. The lil piece of bolt that’s stuck in the backside bracket os in there about 1-2mm if that. I was able to pilot hole drill a hole in the middle but I can’t seem to rea the hole larger. I had some titanium bits but not really cutting through so I can punch through that was long enough so I had clearance to put the drill behind the strut tower and clear the axle.I am thinking of either buying a cobalt drill bit as I read they are good for hardened steel. Either that or I’ll try putting heat on it and either drilling it the rest of the way or I’ll try to punch it through. Thanks for your help.

 
Rep Power: 366

remover drills takes a lot of pressure to pull them out.
any pics?

 
Rep Power: 223

Also, common mistake when drilling metal is to go too fast. The faster the drill bit spins the quicker the bit will dull. Slow speeds and lots of pressure is the way to go.