Snapped rotor bolt in hub: removal tips?

skunkty14 · Jun 29, 2007

Being the ham fisted mechanic that I am I promptly snapped off one of the Torx rotor bolts while mounting my new rotors on my brand new wheelset :madman: :eekster:. So now the search for ideas to remove it: I know I could drill it out, but I'm concerned that I'll ruin the threads in the hub, and thus the whole hub shell or at minimum have to helicoil it. From working on cars I'm thinking of trying a reverse drill bit to see if I can back it out, anyone try this before? Mainly I'm concerned about the locktite that is on the bolt making it hard to back out.

Anyone successfully remove such a bolt before? Yet another reason I should own a torque wrench I guess :nono:

jesterman · Jun 29, 2007

i would opt for the reverse drill or a screw-out-kit. which works like a drill then threads in the drilled hole and backs it out. the difficulty you will have is the small diameter of the screw itself.
is the entire head of the bolt gone?

skunkty14 · Jun 29, 2007

jesterman said:
i would opt for the reverse drill or a screw-out-kit. which works like a drill then threads in the drilled hole and backs it out. the difficulty you will have is the small diameter of the screw itself.
is the entire head of the bolt gone?

The head of the bolt is gone including about 2mm of the shaft, so the portion I need to remove is actually completely inside the threaded hole. Sorry no pictures, forgot to bring in the camera.

Using the reverse drill/screw-out route requires drilling a hole in the bolt first, then using the spiral bit to back out the bolt correct? Been a long time since I've done this.

ZoSoSwiM · Jun 29, 2007

that sucks! good luck!

XSL_WiLL · Jun 29, 2007

Any chance you can thread in another bolt to push it out the other side?

skunkty14 · Jun 29, 2007

XSL_WiLL said:
Any chance you can thread in another bolt to push it out the other side?

Doubtful IMO. There is enough thread to start another bolt, but I highly doubt the base of the new bolt would be able to generate enough grip to turn the existing broken bolt and thus thread it out the flange side.

If anyone has done this with success, please speak up cause it would be an easy, easy fix.

fsrftc · Jun 29, 2007

take it to a machine shop, for a few $$$ you'll be good as new

XSL_WiLL · Jun 29, 2007

We've done it at the shop before.

Is it a clean break? Or kind of jagged?

skunkty14 · Jun 29, 2007

XSL_WiLL said:
We've done it at the shop before.

Is it a clean break? Or kind of jagged?

It's fairly clean, but the surface isn't perfectly flat, there are dips and small ridges in it.

I'm guessing the messier the break, the better your trick will work? Was a regular 5mm T25 long enough to push out the broken portion when you've tried this?

Megaclocker · Jun 29, 2007

Personnaly i would drill it out with a regular bit. Start with a very small one and go bigger. After some try the bolt usually selfdestruct itself and you will be able to take it out easily.

Just take your time and you should be fine ! :thumbsup:

Snapped rotor bolt in hub: removal tips?

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