Super A final drive bolt

[crsutton81]

Working on a SAV replacing bearings and seals in the rear end. Someone obviously has been here before me unfortunately and did a little engineering. The original bolt hole where my finger is pointing at to hold the final drive on has a twisted off bolt really deep into the hole. It appears a really oversized drill bit was unsuccessfully used to extract it which has the hole wallowed out. They're fix was to install a new stud above that and blow a hole into the old final drive casting to accommodate. Being another casting had to be acquired, the bolt dilemma needs fixed. What is the best way to proceed ? Weld the hole shut, drill then tap it ? Any other suggestions ?

 

[Fritz Maurer]

Make up a flat plate that attaches to the adjacent studs, and rent a magnetic drill press.

Since the center line of the hole is uncertain at this point, you're going to want to use a double cut end mill .... that way you can move it around and start a new cut until you're in the center of the hole.... you can't do that with a twist drill.

Use an end mill the tap-drill size of the stud , and when it's on center the the mill will bore the whole stud and the threads will come out like a Heli-coil insert.

 

[rustred]

Might have to leave the sleeping dog lye. There is no oil to leak , it’s not really the correct fix but it’s doing the job. Drill that broken bolt out and u still have the other one to deal with. To drill a hole in your other housing should be easy. On the other hand you could heat that broken bolt red and let it cool and try a reverse drill. But the hole is a mess anyhow. So that’s why I say just put it together