Final stage project disaster: broken bolt in axle end
 

Just finishing up my project tonight...replaced and rebooted both rear axles. Been quite a project.

So, of course, there was one last hiccup.

When I was tightening down the bolts that tighten into the end of the axle (inside the hub), the bolt broke...right at the axle end, so it's too far in there to grab onto and back out.

How do I remove the hub, so I have access to the end of the axle for trying to remove that bolt? And, once I get there, any tips on getting that bugger out?

What is the proper torque on these bolts? Apparently, I put too much on there....

So, so deflating...need to drive to work in the morning! :eek:


EDIT: perhaps I can just pound out the axle again, toward the diff, since there is essentially nothing holding it to the hub...going out to try.

You need a sharp center punch, a high-quality drill bit, a good drill motor, and an EZ-out. Drill a hole in the snapped-off bolt and use the EZ-out to back out the end of the broken bolt.

The torque spec depends on which bolt size you have. Mercedes changed the size and the torque is very much different; if you saw the wrong number you easily could have set your torque wrench too high.

Well, not quite as bad as I originally thought. I did, indeed, pound out the axle toward the diff...I was able to barely squeak the splined axle end out of the hub on the inside.

Then, in a moment of both embarrassment and hilarity, I backed the broken bolt out WITH MY FINGERS. Seriously? Yes. Don't know how, but I don't care. :o

Put the axle back in, used another bolt I had on stand-by, and finished the job. Just got back in from a test drive...pure beauty.

Life is good. I could not believe it, but I'll take it. :D

Aahh yes it is good:)

Those axle end bolts are pretty low torque....I don't recall the number, but its only like 50ft/lbs or less. All of the ones I have removed were easily loosened with a normal small 3/8 drive ratchet.