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 03-02-2004, 07:08 Post: 78475
Blueman



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 VW Lug Bolt Broken

OK, I know alot of you have experience in this area, and I need some input...I broke an aftermarket lug bolt putting on my "summer" tires and wheels on my Jetta TDI...There is nothing left to grab, yet the "flare" on the bolt is still holding the wheel on. I want to remove this bolt in case of a flat, or when I finally get around to the rear brake job that I need. Someone suggested having someone weld something on it so it could be turned, but I think it would be difficult to get that far in the "hole of the wheel" to weld something...any suggestions?






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 03-02-2004, 07:48 Post: 78478
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 VW Lug Bolt Broken

About the only thing that comes to my mind is to thoroughly soak the piece in a very good penetrating oil such as Kroil and try to drill out the bolt to the largest size hole possible and hope that an EZ-out is strong enough to remove the broken piece if I am understanding your description of the problem. I am not exactly sure how the rear axle and brakes are set up on Jetta otherwise I might be able to offer different solution. I take it you may have already considered using an EZ-out.






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 03-02-2004, 10:22 Post: 78494
AC5ZO

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 VW Lug Bolt Broken

I agree with Chief. Kroil works well.

Drilling will help and the EZout is probably the way to go. I like the EZ out style that has straight teeth that you drive into the hole. Some of these look like square punches and some look like straight knurled hardened shafts that drive into the hole and form teeth at the same time. In addition, I might recommend using a countersinking cutter to countersink into the hole on the wheel and it will cut out the remainin part of the flare and leave the countersunk hole in the wheel/rim. (Countersinks are available in a variety of sizes and angles, so you should match to your situation.) It is important to get the hole right down the center of the wheel bolt remnant.

If you can do it, you will probably find that this process is easier with the wheel and hub/(disk/drum) removed from the axle together. I would also make use of heat through the drilled hole if the hub was removed from the axle.

The bolt is probably corroded in place and the Kroil or other penetrating oil will help break up the rust. The heat from a torch will cause differential expansion of the metal and tend to break these bonds also. If it is cross threaded or otherwise bound in position, it will be a more difficult removal task.






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 03-02-2004, 15:23 Post: 78517
AV8R



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 VW Lug Bolt Broken

Blueman: If you use the largest LEFT-handed drill bit you can get in there you may not need to do all the swearing at the broken hardened EZ-out. Had the same problem on my 86 Jetta when I first got it.

Cheif: VW uses lug BOLTS rather than nuts.

AC5ZO: If you are creative with the drill size an impact style "Torx" bit will do what you suggest also.






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 03-02-2004, 16:25 Post: 78521
AC5ZO

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 VW Lug Bolt Broken

I have never tried the Torx, but it is a good idea. The ones that I have use a straight knurl with about 12 to 15 points.






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 03-02-2004, 16:47 Post: 78523
kwschumm



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 VW Lug Bolt Broken

The suggestions above are all good. I've found that when bolts or nuts are REAL tight it always helps to vibrate the area with an air chisel and blunt bit while simultaneously breaking it loose.






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 03-02-2004, 19:33 Post: 78540
hardwood

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 VW Lug Bolt Broken

I think I'd tried every type of EZ out known to man along with every cuss word in the dictonary till a seasoned mechanic friend of mine told me to get a set of left hand drill bits. Usually by the time you've worked your way up to the biggest bit that won't destroy the threads in the casting the hollow shell of the bolt threads conmes out with the drill bit. Hope this helps.






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 03-02-2004, 20:26 Post: 78544
BillMullens

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 VW Lug Bolt Broken

I would try the welding idea. But then I hate to drill and love to weld.
Bill






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 03-02-2004, 20:41 Post: 78546
Peters

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 VW Lug Bolt Broken

I would agree with Hardwood. I think I would punch the center , take a small drill and make a pilot hole. Then take a large drill near the size of the bolt and take the flange off. Once the wheel is off then you can remove the disk and drill out the bolt properly.






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 03-03-2004, 06:49 Post: 78578
Blueman



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 VW Lug Bolt Broken

Thanks for all the input...I knew you guys would come through...a friend of mine told me last night he lent his left handed drill bits to someone, and he thinks he can get the bolt out easily, once he gets his drill bits back! As a sidenote...a local tire dealer (NTB) wanted $200 to get the wheel off...uh, no thanks!!






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Discussion Boards > Active Subjects > Messages as Posted > Just For Fun Off Topic Forum

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