Hi, first post on USMB. I'm new to Subarus, but not new to wrenching on my cars. I plan do the spark plugs in my '99 Outback Wagon this weekend, hopefully I can avoid a similar problem.
I've dealt with plenty of broken fasteners, here's a few hints to add to the others:
- Easy-Outs are evil! They break easily, and are harder than drill bits. A broken bolt containing a broken easy-out is a nightmare to remove. I've never had success with one.
- The Truebite bits probably work as advertised, but they seem a bit expensive for a carbide Dremel bit. If you're in the US, Home Depot and Wal-Mart sell Dremel brand carbide bits for about $5.00.
- Drill out the bolts with a LEFT HAND drill bit. No joke, they exist, industrial supply shops sell them (for example, www.mcmaster.com). You need a reversible drill, of course. Often, the drill will spin the bolt out.
- If you end up drilling them out, you can dill the next size larger and tap new threads. Alternatively, you can use Heli-Coil thread inserts or Loc-Tite Form-A-Thread to create new threads the same size (any auto parts shop should have them).
- Weld a nut to the remainder of the bolt. Hold the nut on top of the bolt with pliers and fill up the hole with a MIG or stick welder. The heat will loosen the bolt, and the nut allows you to put a wrench on it. Probably overkill for these small bolts, but it's a handy trick for bigger stuff.
Hope this helps!
-Ron
Got a chip in my windshield the other day, something hit it hard while driving 75 MPH. It's the "bullseye" type, no radiating cracks. Has anyone tried one of the DIY repair kits? Were the results satisfactory? My insurace will likely pay for a professional repair, but I like to explore my options. Thanks!