mchugh777

When removing my sway bar a guy broke one of the bolts off in the sub frame and now im screwed

samaritrey

Probably would have to drill it and use a helicoil or maybe a reverse drill bit.
Can we get a picture.
Is this "guy" you?

KSKarl

Yes, you'll need to center drill the broken bold and apply a screw extractor (aka ez out). Start by hosing it down with penetrating oil. Then use one of those extractor kits that starts with a left-hand twist drill, so you need to set your drill to reverse to drill into the broken bolt. Sometimes just that is enough to spin out the broken bolt. Then when you have enough of a hole to start the extractor, twist it in and pull the bolt. Work carefully - if you break the drill or extractor in your broken bolt, you'll need professional help.

SeaCoupe

This is good advice. Generally a bolt head breaks because the bolt is stuck in the seat. I would take extra caution here. I strongly recommend PB Blaster for a few days prior to doing the work. Spray it above and then tap to vibrate it into the seat. PB Blaster will break away any corrosion that has the bolt frozen. PB Blaster has gotten me out of many a stuck bolt.

krazzdav

2nd the PB Blaster -- great stuff

mchugh777

The bolt broke off flush with the cradle. I left to pick up a client and a mechanic in my shop decided he would "help out" and tried using an EZ Out after he broke the bolt. Problem is, he drilled crooked and couldn't get it out. I don't know if I can re drill it straight or if trying would be a lost cause because the larger bit will stay in the same crooked line. It's really in there.

KSKarl

Hit it a couple times a day with PB Blaster for a few days. Then try the easy out again. You can't rush this. You could also try some heat on it.

samaritrey

Another thing to try would be using a small drill bit re drill it straight then step it up unit you can use the ezout. Lots of PB blaster for a few days should help as well.

RCPDesigns

Weld another bolt onto it, then back them both out. Before you do that and if the area can take heat, get it cherry red with a small tip on you Oxy/Act. When it cools back down it will shrink at a different rate than the frame and that should help pop it loose. Weld on a bolt and it should come on out. I've done this a bunch and it is really the best way. Bolt/screw extractors are only for when/if you can't weld.

wvadam

I found this out later when I was doing other suspension work, that my mechanic had drilled out one of the holes, maybe larger, and he attached the bushing to the sub frame with a bolt going through the hole and he put a lock nut and washer on the other side.

KSKarl

Yeah, that's another solution.