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E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


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Old Tue, Jun-04-2013, 03:20:17 AM   #1
19shaun79
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Default Broken V-Brace bolt - any suggestions?

Hi.

Lately it's been one broken bolt after another - this time I broke one of the v-brace bolts, the passenger side one that is right beside the jack pad.

Initially I tried to cut a slot into the stuck part and use an impact to turn it out.
Didn't work.
So I tried heating the sh*t out of it and drilling it. 10.9 bolts are strong. Really strong, even when very hot. I ended up going through a bunch of drill bits, including a cobalt one. I am planning on returning that bit, but all in all, my efforts didn't work.

Now what? I am super frustrated with this and am currently driving with no v-brace. My burn out:drive ratio is severely limited by this set-back.

Please help.
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Old Tue, Jun-04-2013, 03:48:54 AM   #2
nrubenstein
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Default Re: Broken V-Brace bolt - any suggestions?

At this point, get out your die grinder and go to town. Small bits, mind you. Do it right and you won't destroy the threads.
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Old Tue, Jun-04-2013, 04:09:32 AM   #3
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Default Re: Broken V-Brace bolt - any suggestions?

What are you doing to the car to break so many bolts?
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Old Tue, Jun-04-2013, 04:54:01 AM   #4
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Default Re: Broken V-Brace bolt - any suggestions?

what is the v-brace for? I placed my jack stand under this once and it bent it in a bit..
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Old Tue, Jun-04-2013, 05:09:41 AM   #5
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Default Re: Broken V-Brace bolt - any suggestions?

not sure on the side ones, but i just had this issue with the center bolt.
had to take the brace off to drop the exhaust and the center bolt snapped.
seemed to be seized in there pretty good. Ended up having to drill it out and re tap the threads.... which was a little hard upside down.
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Old Wed, Jun-05-2013, 12:05:58 AM   #6
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Default Re: Broken V-Brace bolt - any suggestions?

Quote:
Originally Posted by bimmerfan08 View Post
What are you doing to the car to break so many bolts?
Oh man, apparently too much! I replaced the springs and shocks and rtabs. Four of the muffler hanger bolts broke - 3 on removal and one on re-install. All of them very rusted - the studs I mean, I was putting on a new nut.

As for this one - I was just putting the brace back on and I guess I over tightened. I think the bolt was weak to begin with but I figured with the relatively low torque spec and the fact it was only holding a brace in (no shearing action...I don't think) it would be fine.

I was wrong.

Anyway...I guess I'm off to do some grinding. I am really hoping I don't have to tap new threads.

Thanks for the input everyone.
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Old Wed, Jun-05-2013, 12:39:02 AM   #7
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Default Re: Broken V-Brace bolt - any suggestions?

Do you have access to a welding machine? If so, maybe you could weld a nut on the broken piece and unscrew it...

Edit:
something like this:

Last edited by BrokenM3; Wed, Jun-05-2013 at 12:50:55 AM.
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Old Wed, Jun-05-2013, 02:15:35 AM   #8
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Default Re: Broken V-Brace bolt - any suggestions?

Exactly - a dremel will work but take longer. Hopefully you got a centered hole with the drill bit to start out with - makes it easy to use grinder bits. I've ground out numerous bolts this way. As you get close to the thread ID, a tap will clean out the rest; even an ice pic if you go far enough, carefully enough.

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Quote:
Originally Posted by nrubenstein View Post
At this point, get out your die grinder and go to town. Small bits, mind you. Do it right and you won't destroy the threads.
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Old Wed, Jun-05-2013, 03:28:01 PM   #9
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Default Re: Broken V-Brace bolt - any suggestions?

I was able to drill completely through the same bolt (driver's side) with a cobalt drill bit. The drill bit was not damaged to my knowledge.
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Old Thu, Jun-06-2013, 04:59:48 AM   #10
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Default Re: Broken V-Brace bolt - any suggestions?

I don't know if you have a local snap-on tools dealer. But if you are still having trouble with these bolts. get your self a really good extractor set. the Screw in male extractors. What I bough for for exhaust manifold bolts breaking off inside cylinder heads is this

http://buy1.snapon.com/catalog/item....re&dir=catalog

Spins at 75000rpms and sounds like dentist drill. Mine I bought came in a kit with small diamond drill bits and diamond buts

Such as
http://buy1.snapon.com/catalog/item....re&dir=catalog

These will literally push through anything. work awesome for making a center hole for drilling.... or for tight spots where a normal drill cant get in. Expensive yes. Just a though.

Have you tried just blow-torching the bolt and melting the bolt... at best you may have to chase the threads to clean them up, this has also worked for me in the past.

GL with your broken bolts. ive been done this path many times before and they are never fun.
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Discussing Broken V-Brace bolt - any suggestions? in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)