How to get a broken screw out

285 Views 7 Replies 3 Participants Last post by hoser, 9 d ago

Surfcali

Discussion Starter · 20 d ago

Hello everyone, i have a 2006 trx450er. I was doing what was supposed to be a simple oil change and while removing the oil filter cover the long screw broke off about half the threaded area. It is still lodged deep in the screw hole. The extraction bits that i have are too big and I don't know about drilling the screw out. I have thought about using a tap set to make new threading slightly larger at the start of the screw hole and using a shorter screw that is slightly larger. Does anyone have any suggestions or thoughts on my idea? I really don't want to replace the case because of the oil filter screw.

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Bullvine rider!!

· #2 · 20 d ago

Surfcali said:
Hello everyone, i have a 2006 trx450er. I was doing what was supposed to be a simple oil change and while removing the oil filter cover the long screw broke off about half the threaded area. It is still lodged deep in the screw hole. The extraction bits that i have are too big and I don't know about drilling the screw out. I have thought about using a tap set to make new threading slightly larger at the start of the screw hole and using a shorter screw that is slightly larger. Does anyone have any suggestions or thoughts on my idea? I really don't want to replace the case because of the oil filter screw.

Damn that sucks bro, those long bolts are the worst case scenario as far as broken bolts go, your idea could work if you’re very careful, or you would need to find a skilled machine shop to completely drill it out and tap it. Sorry but if not you’re SOL & need a new case.
I almost had the same issue but luckily the boat didn’t break completely it was literally hanging on by a thread as you can see in the pic. Only tighten these bolts with a Light snug ONLY! Let us know how you make out and good luck.

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Bullvine rider!!

· #3 · 20 d ago

Wow you joined 7 years ago? And this is your only post? Must of had no issues up till now 😂

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Surfcali

Discussion Starter · #4 · 20 d ago

Thanks, that's what i was afraid of. I'm gonna go for it and see what happens. Yeah i joined years ago, but usually I'm able to search a problem and find past threads that answer my question. This particular issue is a bit unique. You guys are all great on here. A lot of good advice, plus I'm a certified YouTube mechanic, lol.

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Bullvine rider!!

· #5 · 20 d ago

Surfcali said:
Thanks, that's what i was afraid of. I'm gonna go for it and see what happens. Yeah i joined years ago, but usually I'm able to search a problem and find past threads that answer my question. This particular issue is a bit unique. You guys are all great on here. A lot of good advice, plus I'm a certified YouTube mechanic, lol.

Haha me too. You just use the site for finding answers to problems only, very disciplined. I respect that. Me on the other hand i can get carried away with life storie 🤦🏼‍♂️, as you can see with my post count. people probably think I’m a douche bag 🤣. Let us know how you make out with tapping the hole out, im very curious to see if it works. Good luck

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Bullvine rider!!

· #6 · 18 d ago

What’s up surfcali? How did tapping the hole workout? Any luck?

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Bullvine rider!!

· #7 · 10 d ago

Surfcali I just read a forum where someone broke the same screw (long oil filter cover screw) and what he did was take the case off and was able to unscrew it from the inside of case.
It makes sense cuz it would be sticking out of that end. You could put vise grips on it and simply turn it out. Not sure what you did but figured I’d let you know. Unless it’s too late and you tapped the hole il 🤷🏻‍♂️

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hoser

· #8 · 9 d ago

Yeah I would definitely pull that left cover off and try to remove the broken bolt from the inner case. Even if you had to drill and extract the screw it would be a much better repair than tapping the cover. And like @Bullvine rider!! said, it may just back out.

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