Broken Studs

[big jimmy 91]

Dodge D 60 , from an 89 1 Ton

The studs that hold the spring plate on the passenger side broke off in the housing

They broke below the surface of the housing about 3/16" , also uneven and jagged

Now , what are my options other than drilling and an easy out They look like they have been there since day one

Are there any other options for repairing this "F" up?

 

[cegusman]

I would do the drill and ez out. just use alot of pb blaster and they should come out

 

[Seventy4Blazer]

soak them REAL well with PB blaster or WD... for aday ot two with multiple applications of the stuff. then drill and ex-out...

OR if you have a welder try doing a build up without getting the housing. then grab that with vice grips.

Grant

 

[royjones]

Hello

Hello is the 60 out of the truck if so . do you have a machine shop up there they could probly get those right out . but if your going to do it your self get or borrow a flame wrench to heat it with once u drill or weld to remove it

 

[Zeitler]

irrc , Dodge uses slightly smaller studs than Chevy/ford , 9/16 vs 5/8?

found a pic in this thread http://coloradok5.com/forums/showthread.php?t=45488

 

[Kiwi John]

Even if you're going to drill them your self it will be easier with the axle out of the truck, so you should try & find a machine shop who can mount axle on milling machine for best result,
DIY: Be sure you mark centre of stud accurately. The thread spiral distorts the view and you must allow for this offset. Centre punch and then drill pilot hole with smallest drill possible. then you can progressively enlarge hole and correct for any off-centreness.
LAWSON sell left-handed drill bits which 'bite' stud as they break thru into the space at bottom of stud hole and twist stud out as they turn.
Snap-on do a similar gizmo which has a collet-type tap around a drill bit.
In all cases use best rust-release / penetrating fluid u'v got.
Good luck.
P.s. If you damage thread when drilling, dont worry. You can drill the hole oversize and fit a 'Recoil' thread insert (Helicoil is similar). These are stainless steel and better than new. They bring the thread back to stock size.

 

[big jimmy 91]

Thanks to everyone for their ideas
The diff is still in the truck so the broken studs are going to stay for now.
M buddy just formed a grade 5 u-bolt to by-pass the studs for now and it seems to be holding very well
Just so you know this truck see's very little street use at low speeds (30 mph.)