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Unread 05-31-2018, 12:22 PM   #1
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Default Sheared / broken bolts on Disc Caliper

I have a Club Car DS that I lifted and renovated back in 2012. You can see the process here:

Upgrading a 1999 Club Car DS to 48v

This week I noticed that one of the front disc brake calipers was hanging down, and when I pulled the wheel off could see that four of the six bolts had sheared off, and the other two were missing.

Anybody have advise on extracting those bolts? I've watched videos of people drilling out sheared bolts, or using an Easy Out, but these seem too small to use those methods. I don't want to bung up the threads.

This is the kit:
http://www.jakesliftkits.com/golfcar...isc_Brakes.pdf

The bolts are described as 10 x 32 x 5/8 Flathead Bolts.
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File Type: jpg brokenBolts.jpg (97.6 KB, 0 views)
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Unread 05-31-2018, 08:38 PM   #2
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Default Re: Sheared / broken bolts on Disc Caliper

Use this



And if they donít come right out apply some heat to the spindle with a plumberís torch. Worst case is to drill and tap the holes. If thatís what you have to do, I might consider going a size or 2 larger if it will fit.

When you put it back together, put red locktite on the screws so they donít come loose again.


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Unread 06-01-2018, 07:10 AM   #3
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Default Re: Sheared / broken bolts on Disc Caliper

Is welding them in place an option? My brackets are welded to the spindle on my CC
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Unread 06-01-2018, 03:21 PM   #4
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Default Re: Sheared / broken bolts on Disc Caliper

Quote:
Originally Posted by asphaltmodified View Post
Is welding them in place an option? My brackets are welded to the spindle on my CC
Probably, once the bolts are extracted and new ones installed to hold it in proper alignment. Might be iffy to align and weld without being true and flat against the spindle by bolting it back first.
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Unread 06-01-2018, 03:26 PM   #5
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Default Re: Sheared / broken bolts on Disc Caliper

I bet those drop spindles are cast. If so, probably canít weld them. But worth taking to a machine shop/welder to find out.

Otherwise I agree about bolting before welding.


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Unread 06-04-2018, 09:29 AM   #6
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Default Re: Sheared / broken bolts on Disc Caliper

I ordered some left handed drill bits and bolt extractors, they arrived yesterday. I'll post pictures of my success or failure. In the meantime, every time I walk past the cart, I spray some Power Blaster at the bolts.

I should be asking myself why this happened in the first place? I don't want to go through all the trouble of repairing to have it happen again. Pretty sure I felt it happen, was driving at a good clip and heard a WHAM. Kept looking back to see what I hit, but it was clearly the brake caliper snapping loose for Some Reason.
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Unread 06-04-2018, 10:38 AM   #7
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Default Re: Sheared / broken bolts on Disc Caliper

I would go the extraction try first......if that doesn't work, then the drill 'em out, tap 'em the next size up (which should work like a charm), and the weld last.

I much prefer the option of unbolting 'em. BTW, JMHO but if you had two missing bolts, that may have occurred long ago.....which put to much stress on the remaining bolts....thus causing the shear.

I would also look to replace the bolts with a stronger rated type.
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Unread 06-19-2018, 11:46 AM   #8
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Default Re: Sheared / broken bolts on Disc Caliper

I've resolved the issue by replacing the passenger spindle. There was just no way to get the sheared bolts out because they are so small, and they are so close to the axle. I tried using a tiny left handed drill bit, and actually backed one of them out. But the rest of them had wonky surfaces, and there was no way to start the bit in the middle of the tiny broken pieces.

I talked to Ray in the tech group at Jake's, and he said in 20 years he'd never heard of all the bolts shearing off of a disc mount plate. So I guess I'm the guy on page one? Technically I find it hard to believe, but there is a first time for everything.

So I ordered a new passenger spindle from Jake's, and twelve new bolts. I replaced the passenger spindle, then backed out the bolts on the driver's side and put in new bolts. I used blue bolt-locker just like I did six years ago when originally installing the lift and brakes.

While I was under the hood, I re-adjusted the toe-in which had gotten off a fair amount over the years. As you know, this is done by loosing the jam nuts on both ends of the tie rod and rotating the whole rod forward or backward depending on which way you need to adjust.

Put it all back together, and everything is fine. I'm happy that the front brakes weren't damaged during the incident.
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File Type: jpg frontEnd.jpg (138.8 KB, 0 views)
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Unread 06-19-2018, 10:14 PM   #9
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Default Re: Sheared / broken bolts on Disc Caliper

Quote:
Originally Posted by wwford View Post
...But the rest of them had wonky surfaces, ...
Is that the technical term?

Hey....I'm glad you got it fixed!! Just love the reference to "wonky"!!
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