broke a tap

[Weasel]

working on my axle and snapped off the tap in a blind hole. Broke off just under the surface. Tried working it out with a chisel and center punch but just managed to chip off the only high point and jacked up the punch and chisels. The took a grinder to it and tried to grind a slot in the top, worked sorta but only got a quarter of a turn before it cracked up.

Tried drilling it but yeah that doesn't work when the drill bit and steel are the same hardness.

I'm out of ideas except to try and weld a piece of tube or rod to the tap and then weld a nut to that and turn it out.

Any other suggestions? It's on the diff bolts if that makes any difference.

 

[Jump This]

working on my axle and snapped off the tap in a blind hole. Broke off just under the surface. Tried working it out with a chisel and center punch but just managed to chip off the only high point and jacked up the punch and chisels. The took a grinder to it and tried to grind a slot in the top, worked sorta but only got a quarter of a turn before it cracked up.

Tried drilling it but yeah that doesn't work when the drill bit and steel are the same hardness.

I'm out of ideas except to try and weld a piece of tube or rod to the tap and then weld a nut to that and turn it out.

Any other suggestions? It's on the diff bolts if that makes any difference.

A picture?
Sounds like location is a bitch.....

 

[Weasel]

Dana 44 diff bolt hole, one of the blind ones into the diff tube area. Bad day for diff bolts, busted one off ealrier today tring to tighten then up, drilled it out and got a tap to retap the hole and clean out the rest of the holes. Got the first hole re tapped and then broke the tap in another hole, stupid thing just snapped off.

I did find these:

http://www.waltontools.com/products/remvtap.htm

anyone used one?

Only good thing is it's not under the jeep yet.

 

[5-90]

Dana 44 diff bolt hole, one of the blind ones into the diff tube area. Bad day for diff bolts, busted one off ealrier today tring to tighten then up, drilled it out and got a tap to retap the hole and clean out the rest of the holes. Got the first hole re tapped and then broke the tap in another hole, stupid thing just snapped off.

I did find these:

http://www.waltontools.com/products/remvtap.htm

anyone used one?

Only good thing is it's not under the jeep yet.

Walton Tap Extractors FTW! I've usd them plenty of times to fix someone else's mistakes, and I've saved plenty of parts with them!

 

[Weasel]

Walton Tap Extractors FTW! I've usd them plenty of times to fix someone else's mistakes, and I've saved plenty of parts with them!

sweet have one on order. I'll refrain from screwing with it till it shows up and see if I can get it out.

 

[Weasel]

http://www.waltontools.com/products/remvtap.htm

Update, these things ROCK! I should have ordered on right off that bat and not messed around with any other method. I screwed up the pins the first time i used it cause I was impatient and didn't remove the diff cover and tried to just stuff the tool in the hole. Didn't work so hot.

This morning I trimmed off the bent ends and then removed one of the pins as the hole in the tap was clogged with chips. A bunch of back and forth and it started to loosen up. Was able to put the fourth pin back in and tap came right on out.