1996 Dodge Intrepid Need mechanical/machine shop advice

T_HUNTER2K

MEMBER
1996 DODGE INTREPID
6 CYL
FWD
AUTOMATIC
16,000 MILES

I have gotten a 10mm deep well socket stuck in the end of the crankshaft after inserting it to use to remove the crank pulley. It is a Craftsman 1/4" drive socket. Now, I find I cannot extract the socket. I realize this question may be better answered by a machinist, but thought I'd try and see what advice you will offer. The drive end of the socket is exposed approx. 1/8" from the end of the crankshaft. A large pair of vice grips just won't get enough of a bite to break it loose, and the socket drive handle won't grip well enough to pry against. Have you ever drilled and tapped threads into a socket? I'm to the point of trying that, putting the drive handle in and tightening a screw down onto the drive, but think that the socket may break while drilling/tapping. Ideas? Thanks sincerely for your thoughts.

4 Replies

MHPAUTOS

MECHANIC
31,938 POSTS

Hi there,

Thank you for the donation.

I would either get a die grinder with a very small carbide tip or a small mill end and carefully grind the socket to the point that you can fracture it, or weld something to it so you can get a better purchase on it to dislodge it and when you do give it a good dose of freeze and release as this will contract it slightly and may be enough to aid in removal. Try this and see how you go.

Mark (mhpautos)

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Monday, September 1st, 2008 AT 5:21 AM

T_HUNTER2K

MEMBER
3 POSTS

Is there a special welding process to be used in this case? I think these sockets are chrome moly. Of course, I want to be especially careful being so near to the end of the crank and not damage it, either. I've considered two other options overnight (plenty of time to think).
Tapping the inside perimeter of the socket to thread a hardened bolt in and use the head (with washers underneath) to pry against.
Drilling a drift pin hole through the entire socket (as well as the rachet handle end that goes inside the socket) and inserting a drift pin to hold it together while prying it out.
Still not sure if the socket might shatter if I try to drill it. If so, then I'm in big trouble.
Thanks sincerely for your thoughts and ideas. Oh yeah. My wife thinks she is getting a new car out of this. I'm trying my best to avoid that scenario. :)

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Monday, September 1st, 2008 AT 8:47 AM

MHPAUTOS

MECHANIC
31,938 POSTS

Hi there.

There is no special welding requirements, just be careful and very accurate, you will find trying to drill and tap near impossible, personally I would try the die grinder method first.

Mark (mhpautos)

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Monday, September 1st, 2008 AT 5:34 PM

T_HUNTER2K

MEMBER
3 POSTS

While I was in town gathering items for a new attack on this problem (EZ Out extractor from Sears, etc.), One of my friends came over and made an attempt at extraction. He succeeded in breaking the drive end of a 1/4" drive square off in the end of the socket, which will severely limit my approach to removal.
Will consult local machine shops tomorrow to see how much repair will cost me. Thanks for all your help.

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