I have a 1976 240D with what I suspect is A EURO 1972 220D engine in it. The support bracket that runs from the power steering pump to the right side of the block, the bolt sheered off on the smooth to the block. There is about 3 inches between the block and the battery tray and a structural beam. I have tried cutting a slot in the bolt shaft and used a screw driver and hammer to try to turn it but the bolt is too soft it just deforms but won’t budge an inch. Any great ideas how to get a sheered bolt off with no room for a drill or much else or is this going to give me a reason to chisel the battery tray out and putting the battery in the trunk. At least then I can fix the rusted out sheet metal under the battery tray. On a good note I put a new primer pump in this morning what a world of difference that has made the old one sucked so much air in.
If its not one thing it’s another.
DHS

Wow, you sure know how to come up with hard questions...

How did you make the slot in it with it flush ?

Isn't there a tool make for pulling out sheered bolts? But maybe it won't fit in the area you are working?

__________________

Is there room for those 90 degree drills? No help but...
Long ago before the dremel was even thought of I used to have a old dentist drill setup than ran on belts and pulleys...had the 90 end.

__________________
82 300D....went to MB heaven
90 350 SDL....excercising con rods

Is there room for one of those small right angle drill attachments ? Then an Easy-out or similar.

Or is there room to weld through the center of a nut ? If you have a welder,(MIG would be preferred) I would recommend trying that first. It has to be a good weld and let it cool completely before attempting removal.

__________________
Diesel-guy

If there is anyway at all get to a wire feed welder and weld a cut down bolt head on there. Heat from the welding will loosen it, then you should be able to turn it out. Anyway to drive it to a body shop, or a machine shop?

I used a dermal tool to slot the bolt shaft it did not work great but I thought it would be enough to get it out. In The PI all the truck drivers carry is a screw driver and a rock and they mange to keep there old POS running. No way could you get a 90 degree bit in there I had to use an extension shaft on the dermal tool with some cut off bits that were worn down to the point they were trash except the diameter was good for this, The power steering on this car makes working on that side of the car a real PITA. I see a lot with out PS maybe I should do away with it since I can’t drive it with out the bracket the torque would break something soon with out that bracket to prevent torque twisting leading to metal fatigue or something else breaking. I could cut a deeper slot but then I would really be cutting in to the block no doubt harmless but to jerry rigged for me to slice a big gouge in it

I might just be able to get the wire feed welder in there if I pull some of the crap in the way I think I will try that next. Unfortunately I have to get a report finished for tomorrow so no fun till I am done with that. If it can break and is very difficult to repair you can be sure it will break on me an one else ever had an upper oil pan crack and un weld able in the car I had one that did that and bought one already cracked what are the odds of that?
I could drive it to a shop but I am trying to buy two more MBZ and I am a little short of cash as it is
Dave S

There are criteria which are used in designing the bracket at the factory which do not apply to you.
If you can get a welder into there... you should be able to make a bracket which will fit to another strong attach point...

There is a nice bolt that would work with out modifying the bracket too much it is on the right side of the block where the hump for the timing advance mechanism is, I will have to look into this bolts purpose because nothing is held in place by it. But I think it may be used to tension something in the engine without looking in to exactly what its purpose is. I could be shorting its length buy putting the bracket there screwing up the length causing what effect on its purpose. So I guess I need to figure out what it does before changing its length. This probably has the most promice
Thanks for the help
Dave S