Help! Need advice on stuck bolt in Xfer case

[thearkatek]

So I'm in the process of putting in an ACT 2600 clutch and I ran into one stuck bolt on my xfer case. I can get it to turn a little bit but I have confirmed that it's just twisting the bolt so I stopped. I tried my 350lb-ft impact wrench on it, as well as penetration fluid and heat (although just the heat from a propane torch ).

Just wondering a few things:

Any ideas on how to get it out?

will it be possible to drill and tap if the bolt brakes?

If there is still some of the bolt sticking out when it brakes will I be alright to run it with the other 4 bolts for a while? (I'm running around 300hp). I know I'm gonna get flamed for this one

Any thoughts would be appreciated!

 

[3kgt2nv]

i would be more worried about pulling threads out vs snapping the bolt. i would soak it in penetrating oil and walk away and repeat the process a few times before trying again.

 

[thearkatek]

ya I have been doing that but I don't think the pb blaster is making it very far into the threads... I'll keep soaking it though. Do you think I should hit it with the impact wrench, or just breaker bar it?

 

[3kgt2nv]

breaker bar is less likely to fubar it

 

[pauleyman]

The bolt goes into a threaded hole in the transmission. Be prepared to repair those threads when you get the bolt out.

 

[thearkatek]

I've already got the tap set aside . Fack, what a PITA. I've hammered on the end of the bolt with a centerpunch and I've been soaking it every half hour with PB Blaster. Gonna give it another shot tomorrow.

 

[greekgodchaos]

Just keep using the Clarkson technique and hammer that bolt loose!

 

[thearkatek]

Pretty sure this bolt is going to break. I'll have to drill it out and hopefully save the threads. If the threads get fubar'd, do you think I could run a longer bolt through it and put a nut and washer on the other side? This is actually just making me want to leave the stock clutch in for this year and tackle it next winter.

 

[T is for TURBO]

Blow torch. Works nearly everytime.

 

[thearkatek]

What type? All I have at the moment is a propane torch which did shit-all. I welded some nubs to the middle of the end of the bolt (the end with the the threads) to try and heat it up but it still won't budge.

 

[PrimerPLus]

If breaker bar wont work use impact. If it breaks just drilk it out. Start small and work up to the right size.

 

[thearkatek]

Got myself a propylene torch, and some "FreezeOff". Not giving up yet...

 

[airmail96]

heard that freezeoff is some good stuff.

 

[thearkatek]

I'll let you know how it goes!

 

[NHerron]

Borrow a real torch but for god sakes dont catch something on fire. That would be terrible. And watch out for any seals nearby, although I dont think there is. Then hit it with a real impact, an IR 2135 after you get the female threads hot. Those bolts are big and fine thread, it doesnt surprise me you cant get them out by hand after theyve seized up a bit.

Good luck

 

[thearkatek]

Well a combination of a hotter torch and that freezoff stuff worked. But now I'm faced with the problem of worn out splines in the tcase and on the output shaft....

Anyone have a good condition 23 spline output shaft they want to sell?