Help - Rear Shock Replacements

I have a '78 300SD (W116) and decided that it was time to replace the rear shocks. Before getting too deep into the job, I wanted to make sure that I could easily loosen all the nuts and bolts.

Well, I removed the nuts from the top of the shocks just fine. Three out of four of the bottom mounting bolts were loosened just fine. The fourth broke!!! The head snapped right off of the bolt.

What should I do now? What is the best way to remove what is remaining so that I can properly install the new shock?

Please help.

Thanks,
Richard

'78 Mercedes 300SD
'97 Mercedes E300D
'02 F-250 Powerstroke
'97 Lincoln Town Car
'89 Lincoln Town Car

[haasman]

Drill out the center of the broken bolt. Get an EZ-Out tool from a tool source. Try to start with a drill bit that is about 1/4 the total size of the bolt. gently tap the EZ-Out in before turning it to make sure the tool "bites" into the metal.

Follow the instructions on the EZ-Out package. If it won't budge try a larger set up ( larger drill bit and larger EZ-Out) Try WD40 or something to loosen the crud around the bolt.

If this doesn't work try some heat right at the bolt before twisting it out with the EZ-Out.

[jcd]

I am bolt tapping impaired and couldn't get it to take a bite, so I was able to run a nut/bolt/washer/lock washer through. It was a tight fit, but I was able to get it done. I have checked it a number of times and all is secure and there is no rubbing against the shock or anything else.

I think hassman has the right approach, but I couldn't get it done, so I went with my low tech approach and it has worked just fine.

Good luck

[haasman]

Another great trick to use especailly with allen head bolts that has been mentioned before-

Put some valve lapping compund on the allen and tap it back in again. The compound is gritty and takes up space helping to ensure a tighter fit.