While I was trying to pull my crank pully on I broke the bolt inside the crank. SUCKSSSS ASSSS. Anyway I tried a bolt extractor and failed. My question is how else can I fix this problem. The press fit seems like it would hold without a bolt, but then you are supposed to put like 100 pounds on that bolt. Could I just not use a bolt (it sounds like a bad idea, or can I tap a new hole or what? Any help.

Work in progress
98 GS t3/t04e, hrc Sidemount, tial 38mm, HKS ssq bov, clutchmaster stage 4, wiseco pistons, Eagle rods, Apexi TT, HKS EVC II, Phantom grip lsd, 3in turbo back, Eibach pro-kit, Defi D-gauge EGT,boost, autometer fuel pressure
8-inj setup in the works, HKS AIC III and 450cc injectors

OMG, I'm almost in the same predicament. I'm gonna PM you my home number if you wanna call me. I cant get the pulley on far enough to get the bolt to thread. Plus I left the bolt (not threaded in) in the crank when I used the puller and it owned the first few threads. I got a new bolt (luckily a local dodge dealer had one in stock) and I started it w/o the pulley on and fucked the threads on it. I just went to NAPA for a tap the same thread type as the bolt with no luck. So I'm gonna try to get a longer bolt to pull the pulley on flush and then make a bolt go in.


* I talked to turbo8u and he said the fit is tight enought to hold the pulley on there, the bolt is just to make sure it stays in place. I dont think I'd risk it tho.

well i dont have many words to help a broken bolt in the crank other than take it to a machine shop and see if they can get the bolt out for you. An extractor would do it but it sounds like it might have been crossthreaded if it was that hard to remove.

To install the pulley read the damn manual it tells you not to use the factory bolt to install the pulley. Many guys have had luck heating the pulley in an oven at 350 degrees the install it but what i did wag go to pep boys buy a bolt the same size and threads as the stock bolt just longer. chances are you cant find on fully threaded so i used a die to tap it all the way down to the bolt head. then use a nut and a few washers, thread them all the way on. position the pulley on the crank and thread your new install bolt into the crank. use the nut and washers to force the pulley on. when its fially on remove the bolt and nut/washers and torque the factory bolt on.

As for your broken bolt.....you are in deep crap. you can try to dril it out and retap it, snap on has the correct size tap, cant remember what size off the top of my head but its SAE if i remember correctly.

Terry

96 Eagle talon ESI
Star Stage II - Boost/oil/EGT gauges

97 Eclipse
Greddy header - Apexi N1 3" exhaust - SFMU/return line - Stage 2 6 puck Sprung hub MIBA clutch - Shortened shifter - Koni Yellows w/eibach prokit - Stillen Fr/Rr swaybars - ceramic intake - DEI Keyless entry alarm - Niche 17" Shoks

Waiting to be installed: Apexi AFC, HKS EVC IV, 450 Turbo injectors, GSX Front brakes (need rotors)

Mitchell on Demand copies available

Dude, that is one of my worst nightmares. That sucks so bad, I'm gonna go buy a new bolt now just for the next time I have to put the pulley back on.

I can't give you much advise on the, except if you decide to try and extract it again yourself, be careful. I broke the extractor bit off in a bolt I was trying to extract before. It's a motherfucker trying to drill through the hardened steel of the extractor so you can retap the hole.

A guy I work with has gotten broken bolts out of engine block using the plasma cutter, but I wasn't there to see his methods. Good luck with this man. Let us know what your gonna do.

"Natty Ride"


http://dirty.thisfreedumb.com/

Dont go freakin out just yet...You *may* be in luck. If your crank bolt had clean, good threads, and was easily threaded into the crank, you can try and get a good strong magnet, you know, like the pen looking ones that can retract like a pointer? Stick the magnet in there, and twist out the bolt like you are loosening it. I had this happen also, but it worked like a charm. But this will prob only work if the bolt threads were clean and not damaged so it turns easily in the crank..

13.5 @108 MPH-2.2 60ft(stupid FWD!)
S16G @ 18 PSI/FMIC/Running on MegaSquirt II (Now with sequential
fuel injection)
My webpage: http://eclipsed4evr.home.comcast.net
-1998 Mitsubishi Eclipse RS-T- "Toy"
-1992 Plymouth Laser Turbo AWD(SOLD)
-2000 Honda CR-V(daily)