Re: Crank pully broke off, left half broken bolt...
 

word you have the oil pump on one side and the seal on the other. Out of the car for sure. My best bet is pull motor


angle grinder and get the pulley off



take crank to machine shop



No way imo is that bolt coming off with basic hand tools

Re: Crank pully broke off, left half broken bolt...
 

the fact that the pulley is gone tho takes all the tension off the threads of the bolt that normally hold it in, i would at least try a small LEFT hand drill bit and then an easy out, with no tension on the bolt it just may come out, its at least worth the 15$ and 20 minutes itll take you to try cuz it could save u big

Re: Crank pully broke off, left half broken bolt...
 

if you take the crank to certian machine shops or you might have to send it in, but there are machines out there that can "burn" a broken off bolt out of a hole perfectly without dammaging the crank's threads. I had to do this to a supercharger shaft it cost me about $12 to get the bolt burnt out much better than a $200 shaft. Not exactly sure what the machine is called my machine shop sent it out to another place to have it done.

I think he is trying to say the pulley already came off, thats what the loud clunk was. I would know it happened to me, but the whole bolt came out so I guess I got lucky.

Re: Crank pully broke off, left half broken bolt...
 

ill tell you how to fix this because it happened to me before..

ill admit, i forgot to put the keyway in the crank one time and just tightened up the pulley bolt to hold the pulley on. Went down the road and heard all kinds of clanging. I eventually found the pulley and the alt and power steering belts as well. Hopefully the bolt didnt just snap flush, meaning when you look at it head on its flat. This is rare, the remaining metal is most likely broken in there with some kind of a raised area and lowered area. As turbohf said, once the head of the bolt is sheared off, theres no tension holding those threads in the hole. Get out a torch and heat the crank evenly around the broken bolt inside, then using a sharp centerpunch and a hammer- tap at the raised portion close to the edge of the threads around in a circle to unthread it. Ill see if i can make a little drawling for you.

The easy out may work, but i think thats a grade8 bolt. Their no fun to drill through

Re: Crank pully broke off, left half broken bolt...
 

Thanks for everyones info. I will be getting to this in the next week. Will post up the madness when it happens!

Re: Crank pully broke off, left half broken bolt...
 

snap-on makes a set of extractors that use left handed drill bits, ive used them to fix a similiar situation for a friend

Re: Crank pully broke off, left half broken bolt...
 

Alright so I was just about to extract the bolt and my friend Oscar notices the nice chip where the key goes. Could this have been the failing point of the crank pully? I have another key and crank pully but I dont want to throw it on for the fact that it could mess up again. Suggestions please. Should I do it like that? I would normally just pull the motor and build it but budget is close to 0.

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Re: Crank pully broke off, left half broken bolt... UPDATE!! PIC!!!
 

I'm going to go ahead and guess that chip isn't a big deal. Getting that threaded section out is. Try drilling 2 small holes that sort of form a notch and try a flathead screwdriver or easy outs or drill and retap.

Re: Crank pully broke off, left half broken bolt... UPDATE!! PIC!!!
 

take a center punch and make a a dimple. take a small drill bit and drill about 3/4" to 1" in. work your way up to a big enough drill bit to get a good size ez out in. had this happen to plenty of b7's. get yourself another pulley cuz yours is probably not round anymore where the crank goes. put RED locktite on the other bolt. and your done. i havent had a problem and have also done it to plenty of customer cars.

Re: Crank pully broke off, left half broken bolt... UPDATE!! PIC!!!
 

Bolt Came out!! For those of you who guessed that there would not be any more tension on the bolt, you were correct! Came off pretty simply. Took the drill, make a small hole, used the bolt extractor and it came right off thanks to b20accord.

Alright the next issue at hand. The Chip where the key goes. Like I said above I am leaning to that was the part that failed and not the bolt. I believe it broke at that point then dominoed effect to the bolt. So I want to make sure that pully isnt going to fall off. b20accord is going to weld a lip on it but first we wanted to see if the metals will (bond) if thats the right way of saying it. Like if we can weld the pully on to the crank where the lip is. Thats all I wanna know if they are weldable. Let me know please. Nig Nog Garage baby.

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