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Bolt snapped off in flywheel, how to remove it? Answered

Hi everyone. I was replacing the pressure plate in a nissan navara with a td27 engine. One of the bolts that holds the pressure plate to the flywheel broke. So we drilled a hole and used a easyout. However the drill bit wandered so the hole touches the side of the thread. As a result the easyout wont work. The hole barley scrapes the side so the thread only looks slightly damaged, but ok.

Have also tryed getting a punch on the edge but that wont work either.

Any ideas on how to remove it?


If all else fails, get it taken out by a spark eroder or "disintegrator" - it can be done in-situ,

can you get to the back side of it and re drill the hole or did you already drill all the way through it? drilling all the way through helps

Is there any part sticking out where you could grind a slot into it and use a impact driver (the kind you strike with a hammer) or a screwdriver

As someone else suggested, heating it up and cooling it down can help it to break free, I wouldn't make it go any shade of red or blue though. You can change the properties of the metal. I have also given broken bolts a spot weld with a mig welder which can help to break it free. Either heating method will help breakdown any loctite if it was used

the hammer and punch might work after you heat it up and cool it down.

You could fully drill it out and use a heli-coil

Could you weld something on to it which you could then grip and remove?


3 years ago

Is it lock tight in place other wise slot the bolt and screw driver it out.

If the base metal is non-magnetic then there is an acid that takes and dissolves the screw with little damage to the metal flywheel.

You can do a careful pilot hole and then a bigger one for another easyout try.

Is that on the crank shaft?

Do you have torches?

Heat the broken stud of the bolt red hot then splash cold water on the red hot bolt stud.

Repeat this a couple times.

Then braze a small piece of metal to the broken stud, make sure you braze just the stud and not the bolt plate of the pressure plate, when it cools turn out the broken stud.

The only other option is to take the crank shaft out and replace it or re-machine it.

The pressure plate has so much torque on it you do not want to risk it coming off and coming up through the floor killing you. Having survived a pressure plate coming off it is wicked neat if you live and looks cool on tape.


May have to drill the entire thing out and rethread the hole for a larger bolt.