transfer case removal

[kenzo]

heya guyz, before i start would like to wish everyone selamat hari raya! and sry if im posting in the wrong section, but i need help with my transfer case removal something like ACD is guess, the problem is, i took down my engine and gearbox, and im trying to remove my crank and block, but as far as i know we have to remove the transfer case, the problem is the bolt that is screwed in the driver output shaft area, the head of the bolt had broken, is there anyway to take it out as im doing this at home, thought of taking it to a maching shop but taking the whole engine and gearbox together is really troublesome

i thought of either welding on the bolt with another bolt and screw it out or drill a small hole in the middle of the hole, epoxe it with a small bolt or make a thread and screw it out, really need in help here, really appreciate anyone that could help!

and any1 have any trick or skill on how to remove the TOB?

any1 knows where to purchase a boost pressure switch besides e-bay?

and do any1 know where can i buy an engine stand? i search almost every hardware but none had them, thanks a million!

here is some pics of the broken bolt area

 

[kenzo]

anyone?

 

[alray]

from the attached picture, u r pointing at the spline of a shaft. r u refering to the removal of this spline or are u wanting to remove the case tat is holding the spline which has a broken bolt? the easiest method to remove a shear bolt is with an "easy-out". this is a common tool and u can purchase it from any DIY hardware store in town. U would have to drill a small hole to fit the diameter of the easy-out. below are some links, hope it will be able to help u with ur fix.

Loosening a Tight or Stuck Screw
http://www.brokentap.com/easy-outs.html
How to Extract Stuck Screws.

 

[kenzo]

thanks alot bro! that really helps! yup the spline, the problem is the bolt diameter is very small, i have to drill a very2 shallow hole, will the easy out bit be able to go through and remove it?

 

[keisukosan]

thanks alot bro! that really helps! yup the spline, the problem is the bolt diameter is very small, i have to drill a very2 shallow hole, will the easy out bit be able to go through and remove it?

u mean is driveshaft head?wat gb is tat u post?

 

[kenzo]

evo 8 gb bro, but it seems to be as same as mine evo 4,the pic is in on passenger side, mine is at the output shaft on the driver side, there is a screw inside the shaft, it seems have to remove that bolt first then can remove the whole transfer case inable to remove the engine, is it true? need help here as its hard for me to take the whole engine and gearbox together anywhere...

---------- Post added at 08:17 PM ---------- Previous post was at 08:16 PM ----------

bro i tried searching for the easy out screw extractor, no luck and plus many hardware is close today, will check ace hardware later...any idea where else to get it?

 

[kenzo]

any help guyz? still no luck, im afraid to drill the bolt as its diameter not that big, just wondering, is it possible if i drill in slightly, epox it with drill bit and drill it out?