If you haven’t dealt with it yet, removing a broken bolt or screw with an extractor is something you are eventually going to do in the shop. You never know when, but at some point, you will feel that bolt get spongy or hear that screw crack. Suddenly, the head is spinning freely. Knowing how to extract it can prevent your project from grinding to a halt. Read on to learn how.
Removing a Broken Screw or Bolt: The Process
Removing a broken bolt using an extractor is a relatively straightforward, but it does require some specific tools and a bit of patience. Here are the steps for removing a broken bolt using an extractor:
1. Gather your tools: You will need a set of extractors, a tap handle or T-handle, a wrench or ratchet, a drill, a drill bit, and some penetrating oil. Extractors come in various sizes, so make sure to select the correct size for your broken screw or bolt. The Ryobi extractor set I link to has a quick reference chart in case you aren’t sure.
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2. Clean the area around the broken bolt: Using a wire brush or sandpaper, remove any rust or debris from around the broken bolt. This helps the extractor grip the bolt more securely and prevent any debris from getting into places it shouldn’t. If necessary, use compressed air or a vacuum to get the debris out of tight spots.
3. Apply penetrating oil: Spray some penetrating oil onto the broken bolt and allow it to sit for a few minutes. This helps to loosen any rust and make it easier for the extractor to grip the bolt.
Pro tip: If the bolt is recessed in the hole, you can use a self centering drill bit. These are often used to center holes for hinges, but they work great for this application as well!
4. Using a drill bit smaller than the broken screw or bolt, drill a pilot hole in the center of the broken fastener. Make sure to use some cutting oil or penetrating oil to help clear the metal cuttings.
5.Turn the extractor counter clockwise: Use a drill, tap handle, or T-handle to slowly turn the extractor CCW. The threads on the extractor should begin to dig in the pilot hole you drilled and set it firmly in place.
6. Continue turning the extractor: Once the extractor is solidly in place, use the tap handle or T-handle to continue turning it counterclockwise. The tight grip in the bolt should start the bolt spinning loose. Use slow, steady pressure to avoid breaking the bolt a second time.
7. Remove the broken bolt: As the extractor turns the broken bolt, it will begin to come out of the hole. Continue to turn the extractor until the broken bolt is completely removed.
8. Clean the hole: Use a wire brush or sandpaper to clean the hole where the broken bolt was removed. This will help to remove any debris or rust that may have been left behind. Do this very carefully if the area has moving parts. Debris falling into an engine cylinder will cause problems later on.
9. Install a new bolt: Once the hole is clean, you can install a new bolt if necessary. You may have to re-tap the threads of the hole for a new bolt.
Things To Consider
Again note that some extractors come in sets. You may need to try different sizes before finding the one that fits the broken bolt you’re trying to remove. Also, if the broken bolt is deeply seated, the extractor may not reach it. In that case, you may have to use other methods such as drilling a hole and tapping it.
Patience is also important when attempting to remove a broken bolt using an extractor. If the bolt is severely rusted or corroded, it may take a bit of time and effort to remove it. That penetrating oil used earlier, use it again. Slow and steady wins this race.
Removing a broken bolt using an extractor is a simple process, but it does require some specific tools and a bit of patience. It’s important to make sure you have the correct size extractor for your broken bolt, use penetrating oil to loosen the rust and be patient when turning the extractor. With the right tools and a bit of persistence, you should be able to successfully remove a broken bolt using an extractor.
