While taking out the bolts from the water pump one broke in the block. This bolt goes through the alternator bracket and water pump. It looks like 10 mm in size.

It looks like a drill and easyout job.

Has anyone had this problem before, and is there any brand of bolt extractors that are better than others?

Any tips would be appreciated,

TIA

Is there enough of the bolt left to grip with pliers or something once the water pump is off and out of the way. If not and it is flush then yes it will be an ease out job. As long as the ease out is hard and not some cheap soft item, one brand is as good as the next. You need to grind or file flat then centerpunch well so you can get a hole in the middle of the bolt.

Good luck,

There is nothing more frustrating than having to drill out a broken EXTRACTOR. It helps to turn extractors with a 'T-handle', like those used to spin taps, instead of a wrench, since the 'lateral' torque from the wrench is more likely to break the extractor. I use left-handed drill bits, and often get lucky when the drilling itself frees the broken bolt! Woo-hoo!
These are pretty easy to find. Harbor Freight has a decent set for under $5, but most hardware stores seem to have them as well.

Link to Left-handed drill bits at Harbor Freight

I recently borrowed a set of these Alden Drill-Outs, and now they are on my (lengthy) tool 'wish list'. Super slick idea. Sears sells the 4-piece large set under their own label for $40. Amazon sells them for $45 (free ship). There is also a 7 piece set that includes smaller sizes for around $60. Best of luck.

Link to Alden
Link to Item at Sears
Link to item at Amazon

__________________
1986 300E 5-Speed 240k mi.

Larry, unfortunately the bolt broke one-quarter inch inside the block. It would have been nice to have something to grip onto for removal.

csnow,
These Alden Drill Outs look slick. My fear was that a conventional easy out would break. Apparently, the bolt broke because it is behind a water jacket and it is the threads have corroded to the block.

Thanks for the tips,
Going to town for tools.

I would be surprised if the end of that bolt was actually protruding into a water jacket. I have heard of this being done, but it is not the usual way.

If it is broken off too far in there, it is possible that the drill-outs might not work, since the 'collet' part might hit the casing before it is able to engage the fastener. One shortcoming of this design...

If it weren't for broken and stuck hardware, auto repairs would be at least 50% easier.

__________________
1986 300E 5-Speed 240k mi.

cssnow wrote:
"If it weren't for broken and stuck hardware, auto repairs would be at least 50% easier."

This is so true.


I got the Alden type extractors at Sears today and will attempt removal of the bolt this weekend.

what about a broken bolt head of a hollow bolt like the one for the sls pump preassure, it has like 5mm of thread out of the housing but very tight

my friend was tighting it and ir broke , that bolt has to be very hard to find, its hollow, 13mm and has 3 holes at the end of it.

were it me I would have car towed to a good auto machine shop as is going to be difficult to center punch it dead center and get a straight drill shot.I was half owner of a small machine shop in late sixties early seventies and don't think your problem is a DIY unless you have done this type of break before.........
William Rogers........

The a/c cooler was in the way and the 90 degree head on the drill in that position there was no way to get sufficent leverage to drill. It would have cost over $250 to get the problem fixed in a shop.

I ended up using a dremel and grinding the bolt down enough in the block so the block can be retapped to the next larger size. I had to drill the clearance hole a little bit larger to accomodate this in the water pump. My other choice was to insert a keensert and use a smaller bolt in the block.

I put anti-seeze compound on all bolts going into the block so this will never happen again.

broken bolts are a huge problem, but from what I can see, the ones on my 18 year old benz are holding up quite well as opposed to some VW on which they rust shut after 5 years. Antiseize on all bolts will sure make everything easier. If you plan on keeping a new car cor a long time, take it apart and put it on every bolt

xp

I am 300K is planned replacement time.