Snapped caliper bracket mounting bolt...

[itzjoker]

Here for help again...always running into little problems with this car.

So I snapped off the head of the 21mm bolt that mounts the bracket onto the steering knuckle. Finished changing the pads and rotors on the driver side fine.
I let that damn thing soak in PB blaster as well. I should've driven around hard to heat that up, I don't have a torch or air/electric tools.


What's my best option to get this thing out?

I don't have access to a welder or know anyone. I don't want to pay a shop an hour to get it out.

I could go out and buy a torch and an ez extractor kit. What kind of extractor kit would I need for this big ass bolt?
Does it matter if I get reverse thread? I would have to drill it from the opposite side of the bolt head (no room from the inside).

I can reinstall the old rotors with new pads and temporarily drive to get what I need to extract it. Rotors are shot, previous owner installed slightly smaller size rotors as well and I can see why...they slide off without removing the caliper mounting bracket.

[ottocycle]

I would totally pay a shop an hour rate for them to get it out. By the time you buy the right tools and you spend a couple of hours swearing at the broken bolt, that hour of labor at a shop will seem like a steal. This is coming from a wrench turning engineer. If your hell bent on doing it yourself, buy yourself a good brand extractor kit, soak it over night with PB blaster, put a six pack on ice and go to town. Those bolts are on there tight as shit. I had to use a big ass breaker bar to get mine off. Do not drive it with out all the bolts in for your safety and others.

[itzjoker]

I would totally pay a shop an hour rate for them to get it out. By the time you buy the right tools and you spend a couple of hours swearing at the broken bolt, that hour of labor at a shop will seem like a steal. This is coming from a wrench turning engineer. If your hell bent on doing it yourself, buy yourself a good brand extractor kit, soak it over night with PB blaster, put a six pack on ice and go to town. Those bolts are on there tight as shit. I had to use a big ass breaker bar to get mine off. Do not drive it with out all the bolts in for your safety and others.

I just can't justify spending $100 for a shop to do it when I can buy the right tools for less and gain some knowledge and experience (plus I'm a broke college student). I don't mind spending a couple hours doing it either. I was using a 2ft breaker bar as well and the bolt snapped off..it's like I didn't even touch the bolts holding the caliper mount so I'll be okay temporarily.

Any recommendations on an extractor kit? Can I just drill all the way through the bolt? Not sure how a reverse thread extractor will help since I am drilling it from the back of the bolt, therefore it would have to move counter-clockwise (if the bolt moves) to reverse out the opposite end.

[Grigor@Bestiale]

If you snapped off the head of the bolt and only the stem is left then the bracket is held only by the other bolt. If so I’d definitely advise you not to drive the car at all.
And if so the stem will be easy to get out by drilling with normal (right hand) drill from the other side after soaking it for 10-15 mins with PB blaster (and hit the bolt stem a few times to break any rust/stuff). Probably just the drill will unscrew it, if it doesn’t, then you’ll need a left hand extractor since you’re doing it from the other side.

But again, it may be very dangerous to drive like that so best is not to at all.


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[Nollywood]

I know it’s an annoying expense, but we’re talking brakes here. 1 bolt will not keep the carrier from swivelling when the brakes are applied. It is also possible to break / bend the single bolt left in the process.

If you don’t feel confident extracting it, I would strongly recommend you pay a shop 30mins - 1hour labour to remove. If you remove all obstructions, you could possibly get a mobile welder to remove it. Or to cut down costs, remove the entire knuckle, take it to a shop, and get it extracted.

Good luck!

[Gosser]

Broke college student buys b6s4, sounds like the title to a horror show.

If you could get the pads out and remove the rotor, you should be able to drill it all from outside of the car. You’ll be able to see the back end of the bolt. But for me, I would head up the bracket with map gas(yellow bottle) and use and extractor bit. I have a set from canadian tire(pretty much a canadian harbour freight) and it hauls put stripped bolts all day long. But if it is soooo seized, no amount of extractors are going to get it out. Need more heat like torches.

[itzjoker]

Broke college student buys b6s4, sounds like the title to a horror show.

If you could get the pads out and remove the rotor, you should be able to drill it all from outside of the car. You’ll be able to see the back end of the bolt. But for me, I would head up the bracket with map gas(yellow bottle) and use and extractor bit. I have a set from canadian tire(pretty much a canadian harbour freight) and it hauls put stripped bolts all day long. But if it is soooo seized, no amount of extractors are going to get it out. Need more heat like torches.

It's just an exaggeration. I made sure I searched around for the right B6 S4 with maintenance done and this car has only given me minor issues for the last 5 years. I've saved so much being able to do all the work myself thanks to this forum!

But yes I can take off the rotor without taking off the bracket, but I cannot get the new rotor on since it is bigger than the one that was on. Did some research on the right torches and I'm gonna go with propane since the new 'MAP PRO' gas is essentially propane with a slightly higher temperature at 3x the cost.

[teutoned]

Correct me if I’m wrong. Pretty sure caliper bolts slide thru hanger and thread into knuckle. Whats keeping you from removing other bolt and sliding hanger off of the broken one? Should leave you with plenty of exposed bolt for extraction w/o drilling.

[itzjoker]

Correct me if I’m wrong. Pretty sure caliper bolts slide thru hanger and thread into knuckle. Whats keeping you from removing other bolt and sliding hanger off of the broken one? Should leave you with plenty of exposed bolt for extraction w/o drilling.

Good point! I actually stopped after snapping the upper bolt because I was afraid of snapping the other one as well. But I'll give it another shot when my spare bolts come in. Car actually isn't running now...I think my fuel pump is gone (or something fuel related)...great.

[Ejabour]

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