Hello -

I had a great afternoon putting new seals in the front right caliper (ATE) on my daily driver, a 1979 300TD. Then I noticed the bleeder nipple had broken off. I broke lots of bits and finally snapped an Ease Out extractor bit in the hole. I pulled another bleeder valve off my later model parts car (1982 330SD?) and it looks like the right size so i've got a replacement. My question is can I get the machinist in town to drill out the hole and tap new threads, or is there something I'm missing? Other posts on this forum suggest if you break off an extractor bit than the caliper is hooped. I live in Haida Gwaii and it will take at least two weeks to get a rebuilt caliper up here. Thanks for any advice.

Meredith

Ahh, the old broken extractor problem. The extractor metal is very hard and causes the drill bit to wander, ruining the hole.

Take it to the machinist. You need a drill press and a clamped work piece. The machinist will have to be careful not to ruin the taper at the bottom of the hole and also not get metal chips inside the caliper.

You've got nothing to lose at this point.

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1981 300TD 310k miles
1970 280sel 172k miles
1966 230 Fintail 162k miles

"Where are we going? And why am I in this hand basket?"

Plus two. He can't drill it and then retap it because it will be too large and I've never heard of anyone successfully using a helicoil in a caliper (or slave cylinder). If he is able to drill away at the extractor enough he may be able to drill to the edge of the existing threads and clean out the pieces. I would plan on rebuilding the caliper, though, because there's little chance of not introducing shavings.

Good luck.

I once used a 1/8" bsp pipe plug to repair a wiped out bleeder screw hole. Drilled out the broken nipple and tapped the hole. Bleeding the caliper after was tricky, but no leaks. It is about the next size up.

I'd probably just use it as is until it is worn out and begins leaking. If it needs bleeding immediately that is a different story of course.

There are also kits for drilling out the bleeder and threading in a complete pipe threaded plug with a new bleeder in it. Your machine shop can do that for you.

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[SIGPIC] Diesel loving autocrossing grandpa Architect. 08 Dodge 3/4 ton with Cummins & six speed; I have had about 35 benzes. I have a 39 Studebaker Coupe Express pickup in which I have had installed a 617 turbo and a five speed manual.[SIGPIC]

..I also have a 427 Cobra replica with an aluminum chassis.

Thanks guys. I had to think quick and ordered a rebuilt in California, which my mother in law brought up the next day on the plane. I'll try to get the old one fixed as a spare. The brakes are working better than ever, but the next day my transmission started acting up. At least it's not raining!