Broken screw removal help.

[rascole]

Bought a Alpha air box for the upcoming swap from a junkyard. I knew the MAF sensor was removed but didn't realize both the screws were broke inside the holes. I have a removal kit but these are small and the stainless screws walk the bit. Who has a better idea to remove screws? Or a box lid for sale.

 

[08H3]

Can you cut the plastic away from around the screw and then rebuild it with a spacer and epoxy after you get it out? That's probably what I would try.

 

[rascole]

Can you cut the plastic away from around the screw and then rebuild it with a spacer and epoxy after you get it out? That's probably what I would try.

Was one of the plans but want to minimize destroying it. I usually don't have the patience for small detail oriented work like this.

 

[Exodus]

if it were me ?
i'd grind it down till i got a flat spot in the center of the bolts,center punch the broken bolts and then start drilling out with a left handed drill bit

i'm wondering how a steel bolt got so rusted in plastic it snapped ?? not once but twice

 

[4speedfunk]

Drill out the old ones. Re-tap the plastic to a larger size bolt, (plastic taps like butta). If that doesn't work, or if you want to keep the factory screw size...grab some riv-nuts (McMaster-Carr) and install them in place of the originals screw holes.

 

[Happy Hummer]

You have a wider shot showing what area this is?

 

[rascole]

I have ground down to flat, center punched, drilled small pilot but as soon as I step up the bit it starts to walk. I will likely cut the entire plastic piece out and fab a new insert.

 

[rascole]

I removed a small amount of plastic at a time until I could grab the screw with a needle nose. Fortunately when the plastic is hot, the screws come right out. Note for next time. There is enough of the hole remaining that I can insert a stand-off with some JB weld so I can still easily install and remove the MAF sensor.

 

[Jeepwalker]

The suggestions above are good. I would personally drill and try to re-tap. Drill the hole a like one step slightly larger than per normal ..if you have machinist's bits...so you don't put so much stress on it when you re-tap.

Should be a 30 min job or less if you have the tools at hand....

 

[rascole]

The suggestions above are good. I would personally drill and try to re-tap. Drill the hole a like one step slightly larger than per normal ..if you have machinist's bits...so you don't put so much stress on it when you re-tap.

Should be a 30 min job or less if you have the tools at hand....

OEM screws are similar to a wood screw, no threads. Looks like they were designed to bit into the plastic. That, and NOTHING is ever a 30 minute job on a H3.