Crank Sensor Bolt Busted Off...

Monday · Mar 11, 2022

Crank Sensor Bolt Busted Off... and I have an idea but I don't wanna blow my car up. The fella whom helped me out designing my exhaust suggested I weld a washer on first, then weld a nut on that, filling it in.

This scares me. I'm fairly proficient with my welders but this has "fire and explosion" written all over it.

I really need suggestions. As it is, the car is off the road until this gets done no-matter-what.

Anything might help.

Thanks

lwarrior1016 · Mar 11, 2022

Oh man, you’ve got tons or room around it and a little bit of bolt sticking out. I wouldn’t hesitate to break out the welder. You’ve got a mig welder right?

You could always center punch and drill it out, but the heat from the welder really helps break the steel bolt loose from the aluminum threads.

Absolutely worst case scenario, you have to pull the cover. That would be my last resort though

RAU03MACH · Mar 11, 2022

I see a part of the bolt sticking out of the other side
Can you get a pair of visgrips on that tip tightly
And working it back and forth
Once lose turn clock wise to spin it out the broken side

ttocs · Mar 12, 2022

I had to do something similar and was worried about fire so I had my pops on the ready with an extinguisher in case of but I don't see a problem.

96blak54 · Mar 12, 2022

You got this mang!

Squirt some rust penetrate and let it soak.
Try a good vise grip.

And then if comes to the welder, vlean the area good with brake clean

badass98svt · Mar 12, 2022

Yup , weld a nut on that sucker

d.garza18 · Mar 12, 2022

lwarrior1016 said:
Oh man, you’ve got tons or room around it and a little bit of bolt sticking out. I wouldn’t hesitate to break out the welder. You’ve got a mig welder right?

You could always center punch and drill it out, but the heat from the welder really helps break the steel bolt loose from the aluminum threads.

Absolutely worst case scenario, you have to pull the cover. That would be my last resort though

I second either of these methods. Don’t sweat it, you’ll be fine!

NEURON · Mar 12, 2022

Drill it out, helicoil it.

Monday · Mar 17, 2022

Well, I got the bolt out. Thanks for all the replies. Every one of them.

You were all very encouraging!!

PS I also found out from the "Idea Guy" (exhaust guy whom suggested welding) the Flux-core just makes it harder. I had to improvise. I welded the washer on the nut first, then 'Gorilla Glue'd the nut and washer on to the aluminum cover. After a few minutes, to set the nut, I welded the whole thing onto the broken stud...

IT CAME RIGHT OUT!!! I would also like to think my ATF/Acetone mixture helped a great deal by just spraying on the broken stud and the lightweight silvery white metal of main Group 13 (IIIa, or boron group) of the periodic table housing.

It came out sooooooooooooooooo easy!