Broken sway bar piece stuck in LCA, hex rod snapped, nut rounded off by impact

[Adieu]

Snapped the 8mm rod that holds it, rounded the 18mm nut trying to impact it off



Filed/sawed off the top thinking I'd got at the threaded part so it would just drop through --- no dice I sawed thru a wider part.



Ideas, short of a new LCA? Can I drill the damn thing? Use some sort of grinding drill bit to destroy this "head" so it just falls out (don't see much chance for angle grinding since it's recessed)? Or??

Bottom end approach seems hopeless, the damn thing is in a stupid recessed nook deep in the LCA

 

[Adieu]

....screw extractor?

 

[Bedrck47]

They say a picture is worth a THOUSAND WORDS

However only ONE WORD describes this

PRICELESS

Try a dermal tool with a cut off blade and try to cut the nut off or a grinder

 

[USMCBuckWild]

Just drill it. Center punch it, pilot hole ALL THE WAY THROUGH, follow up with a drill bit that is more than 3/4 of the diameter of the bolt (but NOT larger than the bolt) and drill down to just through the LCA, now drill with a bit that is slightly larger than the “shoulder” that is keeping the broken bolt in place. If it won't drop free you have a “shoulder” inside the bolt you can use to drive it out with a punch. Effectively you are relieving internal pressures on the bolt to help ensure you don’t drill too far and wreck the LCA.

 

[1997SCEBFEX]

all the above.
had one snap on driver's side-old age and fatigue. replaced both.
new ones have a washer on 4 different places to make firm contact (pic refers).
just did this on my '97 last year, went with MOOG. Much improved over OEM. Don't over torque.

 

[Adieu]

Victory.



Hanson EX5 screw extractor kit.

Piloted with 13/64", then drilled out with included 19/64" bit to ~5/8" deep and tossed the extractor in a ratchet.

When the extractor bit in, results were instant

 

[1997SCEBFEX]

great news!

 

[deweysmith]

Glad to see it wasn’t as hard as you thought

Sucks to see it suddenly got harder

Good that you got it out though!

 

[theoldwizard1]

Victory.

View attachment 22984

Hanson EX5 screw extractor kit.

Piloted with 13/64", then drilled out with included 19/64" bit to ~5/8" deep and tossed the extractor in a ratchet.

When the extractor bit in, results were instant

I have a small set of LEFT HANDED drill bits, but they are spaced 1/8" apart. Still they work better than most extractors, especially if you use a drill with a hammer setting.

 

[Adieu]

I have a small set of LEFT HANDED drill bits, but they are spaced 1/8" apart. Still they work better than most extractors, especially if you use a drill with a hammer setting.

Drill bit market has always been a bit of a mystery to me....some of the most obvious stuff is nigh-impossible to find, at least in brick and mortar places

 

[theoldwizard1]

Drill bit market has always been a bit of a mystery to me....some of the most obvious stuff is nigh-impossible to find, at least in brick and mortar places

Which is why I do most of my shopping on the 'net !

Check Drill Hog eBay store. Made in USA and lifetime warranty !

 

[USMCBuckWild]

Which is why I do most of my shopping on the 'net !

Check Drill Hog eBay store. Made in USA and lifetime warranty !

Damn you! There goes another $500....

 

[Adieu]

Damn you! There goes another $500....

...on DRILL BITS????

 

[USMCBuckWild]

...on DRILL BITS????

115 piece drill bit set, step drill set, 23 piece hex head drill set (fits into the hex head impact driver) and sae/metric tap and die set (no question lifetime warranty on all of it). Adds up quick.

$514 bundled together (he cut me a deal on them all) with free shipping.

 

[Adieu]

115 piece drill bit set, step drill set, 23 piece hex head drill set (fits into the hex head impact driver) and sae/metric tap and die set (no question lifetime warranty on all of it). Adds up quick.

$514 bundled together (he cut me a deal on them all) with free shipping.

...how much drilling do you actually do??

 

[USMCBuckWild]

...how much drilling do you actually do??

Whatever is necessary. With age comes wisdom. I have found that in MOST circumstances it is “better to have it and not need it than need it and not have it”.

Why do I need a generator? Power goes out maybe 1-2 times a year. But when power does go out my fridge and freezer get run to keep food from going bad, I have heat and most importantly i have coffee. My neighbors know I have a generator and keep extra gas on hand because they know they (and their kids) are welcome here.

Neighbor breaks a bit and doesn't have a duplicate; I got you. Need to utilize an obscure size bit for woodworking/gunsmithing/hobbyist/home-repair/vehicle-repair/general-debauchery; I have one on hand and don’t have to drive to Big Box store to buy 1 overpriced bit.

I’ve been that guy who couldn’t afford more than simplest tools and longed to be able to afford stuff I needed. Now when I have the chance to get something that I know will be utilized again in the future: I do.

 

[ExpeditionAndy]

Whatever is necessary. With age comes wisdom. I have found that in MOST circumstances it is “better to have it and not need it than need it and not have it”.

Why do I need a generator? Power goes out maybe 1-2 times a year. But when power does go out my fridge and freezer get run to keep food from going bad, I have heat and most importantly i have coffee. My neighbors know I have a generator and keep extra gas on hand because they know they (and their kids) are welcome here.

Neighbor breaks a bit and doesn't have a duplicate; I got you. Need to utilize an obscure size bit for woodworking/gunsmithing/hobbyist/home-repair/vehicle-repair/general-debauchery; I have one on hand and don’t have to drive to Big Box store to buy 1 overpriced bit.

I’ve been that guy who couldn’t afford more than simplest tools and longed to be able to afford stuff I needed. Now when I have the chance to get something that I know will be utilized again in the future: I do.

I'm with you. I'm a tool guy. I'd rather have it than not need than need it and not have it.