early 70 dana 44

I changed my axle fluids of my 70 cj5 I just got on the road last week. the 27 fluid seemed fine but changed it. The 44 is extra thick like lots of the power punch stuff has been added, I tried using the pump to pump fluid in, to pump it out and it was to thick and made the p/u straw shoot out of pump, of course it fell in the pumpkin.( lots of cussing followed) So I figured I would take off the cover plate. I snapped of the first bolt I tried after letting them soak for an hour.

What should I do at this point. I resoaked the bolts with PB but I don't want to snap any others off. what is the best way to get the broken bolt shaft out.

 

Use left handed (reverse) drill bits. Use a center punch first to get your starting piont. then start with a small drill bit and use cutting oil in a spray can. then work your way up to the next bigger bit untill the stud comes out. (go slow so you won't burn up your drill bit tip and use a lot of cutting oil) Some one probably used red lock tite on them. good luck

 

I've had good luck heating the bolts, then spraying oil between the head and the bolt, then tapping the head with a hammer. you might try heating the housing up where the bolts are to see if they come out easier.

next question, do the heads have any markings on them? like lines or writing?

depending on where the bolt is, it could have rusted as some of he holes aren't blind. might be able to remove from other side.

then make sure you use neverseize on the NEW bolts.

 

If you have any amount of the bolt coming out above the housing, I've taken a torch and gotten it red hot, then touched it with a stick of parrafin wax while it cools. Several occasions, it's just backed out with a pair of locking pliers.

 

thanks again guys for the advice

 

what i do is take a nut a size or two larger than the broken bolt and weld it to the bolt, even if it broken flush or slightly lower. The welding won't stick to the cast iron diff housing, and usually the combination of heat from the welding and the nice large nut will make it easy to thread out. If it doesn't work with the first nut you weld on, then it usually will with the second. I have never had it fail me, and works great on any bolts broken off in cast iron, heads, blocks etc. I will see if I have any pics of the last time I have done it.