Passat TDI CRANK SHAFT BOLT

Tiny
JC1WAY
  • MEMBER
  • 1996 VOLKSWAGEN TDI
  • 1.9L
  • 4 CYL
  • FWD
  • MANUAL
  • 155,000 MILES
THE CRANK SHAFT BOLT BROKE OFF IN THE CRANK. DOING A TIMING BELT. WHAT IS THE BEST WAY TO REMOVE THE BROKEN BOLT. DRILL AND EZOUT?
IS THERE A PIN ON THE CRANKSHAFT PULLEY. HAVING A HARD TIME REMOVING THE PULLEY
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Thursday, March 31st, 2016 AT 11:33 PM

3 Replies

Tiny
CARADIODOC
  • EXPERT
There's usually a square key between the crankshaft snout and pulley hub.

To get the bolt out, if it is broken off flush with the snout, fashion a way to hold a rather large nut on the end, heat the broken bolt with an acetylene torch for a few minutes, then use a wire-feed welder and weld to the bolt. Don't stop or take a break until the weld builds up and fills in the center of the nut. The goal is to get the bolt as hot as possible. The heat is going to be sucked out of it very quickly, and the weld won't penetrate if the bolt is not hot enough to melt. A propane torch won't work for this.

Once the center of the nut is filled in, wait about ten seconds, then dribble a little water on it to shock the bolt, then you can use a socket on the nut to remove the broken bolt.

I've used this trick for much smaller thermostat housing bolts. When those are threaded into aluminum, that removes the heat very quickly. I've already had to resort to doing this five or six times before the bolt came loose.
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Saturday, April 2nd, 2016 AT 4:35 PM
Tiny
JC1WAY
  • MEMBER
We were
able to drill into the bolt and use a spirel extractor. Bolt came right out.
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Saturday, April 2nd, 2016 AT 8:28 PM
Tiny
CARADIODOC
  • EXPERT
Dandy. At this point I think you can forget about welding a nut to the bolt.
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Sunday, April 3rd, 2016 AT 8:15 PM

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