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Bolt on transmission snapped, how do I remove it?

Tiny
BRETT4USM
  • MEMBER
  • 1989 FORD BRONCO
  • 5.0L
  • V8
  • 4WD
  • AUTOMATIC
  • 120,000 MILES
I was tightening the 13mm nut that holds the throttle lever to the lever that shifts transmission into gear. Any suggestions on how to replace or if I can have the lever tac welded to the shift lever? (Just a thought)
Pic attached.
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Sunday, February 5th, 2023 AT 4:10 PM

7 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,400 POSTS
Hi,

The only thing to do is to drill it and try getting it out with an easy-out tool. If that isn't an option, you will likely need to drill the threaded portion larger and rethread the shaft and then replace the bolt.

As far as spot welding it, anything is possible, but that is a tough one to answer. I wouldn't make it a first choice.

Let me know if you have other questions.

Take care,

Joe
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Sunday, February 5th, 2023 AT 5:53 PM
Tiny
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  • 15 POSTS
Do you know if that is a screwed in stud or if that leads to a shaft that goes through the transmission? I have tried to find a schematic of the transmission, but I can’t bond anything on that specific part.
I am curious if the stud will come out without breaking down the transmission.
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Sunday, February 5th, 2023 AT 6:11 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,400 POSTS
Hi,

I believe what I am seeing in your pic is a C6 transmission. If that is correct, the part that is disconnected is the down-shift lever.

If that is the case, then the trans needs to come apart. Do me a favor. Take a look at the pic below that I attached and let me know if that helps. If that is the correct transmission, that shaft goes inside the transmission to a kick-down lever.

Let me know.

Joe

See pic below.
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Monday, February 6th, 2023 AT 7:57 PM
Tiny
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  • 15 POSTS
I believe it is an AOD. I was told to look at the transmission fluid pan on the bottom and it is shaped like the AOD. Almost a square.
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Monday, February 6th, 2023 AT 8:19 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,400 POSTS
Hi,

It will still require removing the pan and replacing the part. Take a look at pic 1 below. The tool shown is being used to remove a roll pin. This is along where the gasket sits.

I attached three other pics showing the pan used for the different transmissions used on this vehicle. Let me know if it is the AOD.

Take care,

Joe

See pics below.
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Monday, February 6th, 2023 AT 9:13 PM
Tiny
BRETT4USM
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  • 15 POSTS
Awesome. I really appreciate it. Do you know of a hack to remove the pin without purchasing a $125 puller? We used to punch them out on our farm equipment, or drill them out.
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Tuesday, February 7th, 2023 AT 5:22 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,400 POSTS
Hi,

That's how we did it as well, but it won't work in this situation. As far as a different way, if you are really careful, you could try to drill it out, but the steel used is tough. Also, you could try to make your own tool small enough to thread into it.

I wish I had an easy answer. Let me know what you decide or if I can help.

Take care,

Joe
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Tuesday, February 7th, 2023 AT 7:54 PM

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