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snapped bolt off transmission pan twice
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tilopa
User
Feb 12, 2014, 10:14 PM
Post #1 of 10
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snapped bolt off transmission pan twice
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2000
Lexus
ES 300
3.0 V6
145k
This is embarrassing. I was trying to stop a leak on my trans pan and tightened to much and snapped the bolt. Took the pan off and drilled a small hole in the bolt then took an easy-out and tried to back the bolt out but the easy-out broke off. A friend told me to just put some RTV on the surface and on the new gasket surface and it should be good.
But then when putting the pan back on I tightened another bolt too much and it snapped.  I know I should have been using a torque wrench, it is amazing how fragile these bolts are and how little torque will cause them to snap, I was using a 1/4 socket wrench with a 10mm socket and holding it at the head of the wrench.
Any advice on how to get out of this one? My friend is telling me we should drill a new hole next to the broken ones and tap it, but I am reluctant to mess around with the aluminium housing and don't want to make things worse. And I have not had much success with the easy-outs.
Thanks.
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
Feb 13, 2014, 1:17 AM
Post #2 of 10
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Re: snapped bolt off transmission pan twice
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This could be an amazing amount of trouble now. IMO you need tools stronger than broken off EZ-out metal and yet another that's reversed. It could still fail. Now you've done it again.
Time to send this out as IMO you are about ready to need another transmission just for this,
T
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nickwarner
Veteran
/ Moderator
Feb 13, 2014, 7:16 AM
Post #3 of 10
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Re: snapped bolt off transmission pan twice
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If the bolt is snapped off flush or very near flush, put a nut over top of it and zap it with a MIG welder. Let it cool for a minute and then try to gently back it out with a wrench. You aren't going to get that one with the EZ-Out snapped in it any other way, that steel is tool grade and a drill bit isn't going to be able to cut into it. On the other hole that isn't broken off, if this is below flush where you can't weld on a nut, use a transfer punch to mark the dead center and use a left-hand drill bit on it. Work your way up in sizes. You can try an EZ-Out but you must be very careful. If it isn't going to go then get the tool out before you break it. Get a Heli-Coil kit for that thread size and use the drill bit it has with it. You MUST have a pilot hole already to do that, and it MUST be at dead center. If you just try to drill using the hole as a guide the bit will walk off the steel of the bolt into the softer and more easily cut aluminum, and then you're looking at pulling the trans and going to a TIG welder for case repair.
Gooping RTV on it isn't going to seal it, and I wouldn't be going and trying to drill in extra holes either.
I hope you used a wire wheel to clean off the threads of your bolts before you put them in. Remember that the torque for this is in inch-pounds, very little. These little bolts aren't difficult to break and as you can see are no fun to remove. Broken EZ-Outs are even worse. I'm up in the rustbelt, so getting broken bolts out is pretty common for me. Took me the longest time to learn ways to not snap them in the first place but sometimes you just can't stop it from happening.
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Hammer Time
Ultimate Carjunky
/ Moderator
Feb 13, 2014, 7:23 AM
Post #4 of 10
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Re: snapped bolt off transmission pan twice
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If that bolt broke from merely over tightening and not corrosion you should be able to turn it out with a pick before you destroy everything with a drill.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
Feb 13, 2014, 11:30 AM
Post #7 of 10
(2254 views)
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Re: snapped bolt off transmission pan twice
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tilopa - send this out unless you have all the equipment. Two broken, one with a broken EZ out is going to take some finesse and know how or make it all worse or a total disaster.
Worse is somewhere along the way the bolts probably were over torqued already making them easier to break? Not there looking but guess that. It probably wasn't the cause of a leak to begin with adding insult to injury. Over torqueing can MAKE them leak! You check pans with gaskets with a straight edge and look for flaws when it's out.
What is broken off probably isn't tight in the threaded hole now hence the suggestions. If flush except for the EZ out a pic or who knows - maybe a tiny Dremel to make a slot so a screwdriver would take it out. I'm not looking at it or how tough the spot just spitting out ideas. Just try not to do something that makes it even worse than it is now or send this out as already suggested,
T
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tilopa
User
Feb 14, 2014, 10:54 PM
Post #8 of 10
(2235 views)
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Re: snapped bolt off transmission pan twice
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Thanks to all.
I ended up using a reverse drill bit on the second bolt and was able to get it out by using an ez-out very cautiously. I just left the other bolt as it was and used a gasket maker product called the right stuff that others had said was an excellent product. So far no leaks.
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nickwarner
Veteran
/ Moderator
Feb 15, 2014, 10:46 PM
Post #9 of 10
(2224 views)
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Re: snapped bolt off transmission pan twice
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I do like right stuff, but it will be put to the test by not having a bolt in there to spread out the load of the pan. If it works thats a good thing. Just make sure you keep a good eye on this for leaks. The fluid itself is expensive enough, the trans is even more.
Glad you got that other bolt to come out.
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Hammer Time
Ultimate Carjunky
/ Moderator
Feb 16, 2014, 6:02 AM
Post #10 of 10
(2221 views)
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Re: snapped bolt off transmission pan twice
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I still think that bolt would have come out easily without drilling if it broke simply from over tightening.
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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