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2G Front Crossmember Bolts Broke

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marcman804

15+ Year Contributor
484
10
Mar 5, 2005
Cumberland, Virginia
I have a 97 GST and when I removed the front crossmember the bolt heads broke off on both bolts. I'm trying to figure out the best way to fix this. I was thinking of trying to drill them out and put in helicoils. Does anyone have any suggestions. Thanks
 

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You can try an ez out, drill and tap, or try to helicoil. Any of the options won't be easy though IMO. I tried to use an ez out on my head to get a broken stud out and it ended up breaking the ez out inside and made the job 10x harder to fix. I'd just try to drill it out and depending on the condition of the threads, run a tap through it or drill out bigger and helicoil.
 
Thanks for the replies. I tried an ez out and the crap broke off so now it's going to be really tough. Any specific drill bit that would penetrate the ez out? Seems normal drill bits won't even scratch it LOL.
 
Thanks for the replies. I tried an ez out and the crap broke off so now it's going to be really tough. Any specific drill bit that would penetrate the ez out? Seems normal drill bits won't even scratch it LOL.

That's the same problem I had. First I tried different drill bits, but none were hard enough and dulled out quickly. I ended up getting some strong bits for my dremel and went to town on it and finally got it after a while.
 
Step drill the bolts using something like a cobalt drill bit (Rigid Brand) from Home Depot or any local hardware store. They may be repackaged as Milwaukee now though. I had this happen on my 90 Laser project. Use a slow speed with plenty of lubricant (I used PB Blaster). I used a Heli-coil on mine, and seems as though it should hold up just fine. Be prepared to make an investment if you have to buy the repair kit. I believe it is an M10 x 1.25. another opinion would be a Time-sert.
 
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