broken bolt??? HELP!!!

[Bosstin87]

2004 ezgo shuttle. went to remove the bolt on the rear clutch so i could change out the cam and spring but the bolt broke.... Best way to remove???

[trig123]

Drill it out and use an ease out. Its a 5/16th bolt and shouldn't be that tight. Just make sure you drill it with the correct bit and straight in center. I use these. They have never failed me.

I know this set is probably not an option for you but just giving an example. its an art to getting broken bolts out. Take your time. Got to be straight in center. Drill all the way through the broken bolt.

[Bosstin87]

the problem is to get to the bolt its like 4" through the clutch. i can get the drill bit in there but my ease out is not that long. so im going to weld the ease out to a extension to be able to reach it.

[CP241]

The shaft is splined and the clutch should slide off fairly easily. Maybe use a piece of a 2x4 and a mallet to give it a couple whacks if its stuck good, but it should slide off without too much fight

[Mooncarter]

Assuming that bolt has right hand (tightening) threads it might be worth it to drill it out using left hand bits. That way if the bit binds it won't drive the bolt in further.

[trig123]

Originally Posted by Mooncarter

Assuming that bolt has right hand (tightening) threads it might be worth it to drill it out using left hand bits. That way if the bit binds it won't drive the bolt in further.

The bolt is right hand threads and I like your suggestion of using the left hand bit. As CP241 stated you use that 2x4 and knock it off.

Might need to jack it up and spray some Kano Kroil Penetrating Oil on it and let it sit for a while if it is stuck. Then you should be able to get that broke bolt out. Might not even need the ease out if you use the left hand bit. .

[Mooncarter]

Originally Posted by trig123

The bolt is right hand threads and I like your suggestion of using the left hand bit. As CP241 stated you use that 2x4 and knock it off.

Might need to jack it up and spray some Kano Kroil Penetrating Oil on it and let it sit for a while if it is stuck. Then you should be able to get that broke bolt out. Might not even need the ease out if you use the left hand bit. .

And like you said above trig, it is very important to start in the center. Use a sharp punch to get the bit started in the center.

[trig123]

Originally Posted by Mooncarter

And like you said above trig, it is very important to start in the center. Use a sharp punch to get the bit started in the center.

Yes very important Mooncarter
You name it and I have seen it over the years on the mess some make. Mostly from getting in a hurry. Then there are those who break the ease off or drill bits when trying to get a simple bolt out.
These bolts are not bottomed out. They do get stuck but to be honest I have never broke one.

We did have a cart once that would break that bolt while driving it. I retired a few days after it broke for the first time and left it with the mechanic to deal with.

I asked him a while back if they ever solved the problem. He said after it broke two more he just parked it as it was a maintenance cart. He installed a different clutch and belt and it still did it. He said he it was no problem getting the broke bolt out .

I have been gone almost 9 years and the cart is still sitting under a tree there. Not sure what caused this but it was not my problem anymore. I always wondered why this happened.

[Dabble Inn]

Yep yep, left handed bits are the only way to go. IF the bolt is not bottomed out the drill bit itself will usually catch it enough to back it out, but if it does then you miss out on the fun of using an easy out

[Blind Old Coot]

Just a thought...if the bolt head is broken off then the clutch should come off. Maybe not easily but that would give you a broken stud to work ftom.

I ended up with a 4x4 under the driver's side wheels to drip oil/ lubricate in the hole and rotated every now and then. The extra slant will allow oil to seep in.

Sadly, I used a 2x2 to wack the clutch off from the passenger side as I was rotating and the thing finally came off.
Just a thought.