Hi
This is my first post. I’ll try to be brief but thorough. I’ve destroyed the top bolt hole
that holds my starter to the transmission. The bolt was seized, I tried to work it back and fourth slowly and it still broke. The motor is out of the truck so I have a clear shot at the broken bolt. I tried heating it up with an acetylene torch to remove it that way, but I put too much heat on it and warped the blind hole, it is deformed now (See Pic). Tried to use a hammer and chisel to turn the bolt and every time I hit the bolt it chipped. Last option I could think of is using and easy out bolt extractor…...well It broke that in the hole also. In trying to get the broken extractor out I used an air chisel with the pointed end. It kept walking off and would hit the transmission housing as you can see with the huge divots by the starter hole. My final thought was to take my dremel tool and cut length wise down the hole to relieve pressure, but that voice in the back of my head is saying don’t do that. To summarize the hole is melted, has a broken bolt and extractor in it. Any help is much appreciated.

 

This is a good challenge for your patience.

If you can get a piece of flat steel, about 3/8 in thick.
Make a hole in it the same size as the bolt hole in the housing. secure that plate to the housing with vise grips or C clamps
Iif you aimed your torch at that hole with the hardened tools of tool steel, you will be able to take the temper out of those broken tool parts once they cool and very likely with a carbide drill bit a little smaller than the original bolt be able to drill our those broken pieces. You may be able to get the broken original bolt part out with another EZ OUT, .This will require your patience and perseverance , but I believe you can do it
Nice to look back when you solve one of these problems. Hang in there !.

 

Thank you, I'll try your idea next week. I'll keep you posted. The only reason I'm trying to save her is she's a stick shift and you can't find them anymore.

 

As you know, go slow and with good planning , these things test your patience.


Something I forgot to mention.
When you are attempting to rethread a blind hole, there are "Starting taps and Finishing taps".
The starting tap is used to get the rethread started until it bottoms out at the bottom of the hole. Once you get there, use the finishing tap to thread in further. You must clean out the cut material after cutting the thread frequently.