Bolt extraction...

I recently bought a used intake manifold from a Mopar swap meet. After getting it thermal cleaned and painted I realized as I was putting the carburator on that there was half of a bolt stuck down in one of the four holes. I bought a bolt extraction kit but I have been told two different ways of doing this.

So... Do I simply drill the bolt extractor in reverse all the way down inot the screw until the bolt starts unscrewing?

Or do I drill a tiny hole in the screw and then drill the extractor into the hole?

And if neither of these is correct then may I please get a step by step answer?

You drill a hole in the center of the broken bolt then use a hammer to tap the extractor into the hole. Then you back the screw out by hand with a T handle used for tapping. An adjustable wrench or power drill will most likely break the extractor.

Al's method is correct for the "old" style extractor that looks kinda like a tap with elongated, shallow "threads" that have a "left hand twist".

If you bought the newer style extractors that have the two pieces with the point looking something like a two bladed counter sink bit, and an upper piece that looks something like a nut then that is used in a reverse rotation drill. If you bought it new it should have an instruction sheet with it. Ignore the usual male impulse and read them. These take some getting use to.

Then if you get it all screwed up you can learn about helicoils.;)

Bolts broken off in aluminum always seems to be harder to remove, due to the reactionj between the 2 different metals. Put lots of penetration oil in there to kill this reaction.

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Originally posted by poncho62
Bolts broken off in aluminum always seems to be harder to remove, due to the reactionj between the 2 different metals. Put lots of penetration oil in there to kill this reaction.

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steel bolt stuck in aluminum can be removed chemically I think the chemical is Alum and you build a damp to hold the fluid and soak for several day in alum I believe it can be gotten at some drug stores. It will eat the seat and not the aluminum. This is from what I wrote have not done it mayself, may want to do a search on the alum. Ed ke6bnl