Hey everyone,

I was installing top speed aluminum pulleys on my water pump and alternator. And I ran into a problem. As I put the new water pump pulley on, I snapped a bolt right off Car runs fine, but i would rather address the problem. Thats what i get for tightening by hand w/o a torque wrench (the bolts are super tiny!).

Cant get the pulley off due to bolt being stuck, so what are my options??

 

Definitely a can of worms. Without seeing the bolt I can only ask questions. How much, if any, of the old bolt is protruding through the mount plate? Is there enough to grasp it gently with vicegrips? f not, what size is the bolt? Is it substantial enough to drill it with a small bit and use an easy-out (screw extractor) to remove it? Also, if drilling is needed, is there enough clearance between the pulley and rad to get a drill in? If not, you may have to drain the coolant and remove the water pump and either drill and extract it or take it to a machine shop and have them do it for you. If the latter winds up being the case, make sure you have a new water pump gasket and/or silicone ready for the re-install.

 

You might be able to turn it from the back after you remove the pulley as well. Could be just enough bolt through the flange to get on it with vise grips as Mysterion pointed out for the front.

 

Use a nut and preferably weld it or try jb weld to the remaining screw. Then use a wrench to remove it.

 

The remaining part of the bolt is maybe 1/8" sticking out from the mounting plate. I can't grab it with vice grips. Was really hoping i didn't have to drill it, not way to experienced and wanted to avoid damage if possible

 

If you can get at it from behind, as dxjp suggested, try turning it out through the pulley and towards the rad. This will avoid turning any possible damaged thread through the mount hols and possibly damaging the thread. Also, if you can turn it towards the rad, once it protrudes further out, you should be able to grab it with vice grips and spin it the rest of the way out.

 

Alright, I will give that a try, thanks for the advice!

 

When you finally get it out, don't over-tighten the replacement bolt. Instead, put some red Loctite on the thread and thread it in tightening it til snug then 1/4 turn more. The Loctite, when dry, will prevent the bolt backing off through vibration.

 

If there's a torque spec, get a torque wrench. Small bolts are so easy to overtighten.

With 1/8" sticking out the back, think long nose pliers rather than vice grips. Another possible removal method would be to cut a slot with a Dremel, then use a screwdriver. But taking it to a machine shop, as Mysterion suggested earlier, is also a good idea if you haven't done much of this kind of thing.

Ken

 

I have a dremel at home, so if the needle nose don't work that would be another option. Ill for sure grab some loctite though. Live and learn from those small mistakes!

 

If it is still in there, a picture would be nice.

If it is protruding from BOTH sides, I would position vise grips so that each jaw is on the end of the bolt, then turn it that way.

Hope it helps.

 

Ill try out all of the suggested techniques and if its still stuck ill snap some pictures. Car is in storage right now but I'm gonna be working on her next week

 

If you can get a dremel cutting disc to cut a groove in the broken bolt you might be able to get a flat screwdriver on there. There shouldn't be too much torque on the blot. Good luck!

ps Sorry, just read that is what Ken-x8 suggested. Anyway, go for it