Basically. The bloke i bought this off has tried to bodge it up. Now i need it fixing. The first original hole has a bolt snapped off in it. Then they have drilled a new hole and then there was no thread.

 

Am i best taking the existing bolt out. Getting it all welded up. Then redrilling and tapping a new bolt in. 

 

I AM NOT BUYING A NEW GEARBOX. I dont have the funds.

Welding a gearbox can be tricky. VAG don't use a pure aluminium its part magnesium which can make welding interesting.

 

I'd use an insert of some description unless you can get away with going up a size.

This has happen to me, box repaired with helicoil type insert

 

 

 

- will be stronger with a helicoil too - heard of them being used as a preventative measure

 

- will be stronger with a helicoil too - heard of them being used as a preventative measure

 

Yeah we did have a bulletin on some gearboxes to do it.

I usually drill them out. I use the same procedure as in

http://www.briskoda.net/forums/topic/288076-best-way-to-remove-snapped-disc-locating-screws/#entry3415251 but with bigger drills. It's slightly more difficult because the holes are blind and you are drilling upward. You will need to use a bottoming tap to finish off.

Drill a hole through the bolt with a drill bit big enough but with some meat still in the old bolt, for an extractor or an easy way is the 2 bolt method, tap a thread into the hole stick a bolt down with 2 nuts on, and crank the bottom nut till in comes out!

The first bolt thread mine gave up last week whilst being fiddled, my mate helicoiled it.

 

 

Fair play I was quite impressed with how well it worked 

The reason why they snapped is cos there stretch bolts and must be replaced when backed off

The reason why they snapped is cos there stretch bolts and must be replaced when backed off

 

I'm pretty sure they arent stretch bolts. They arent tightened up enough to put an M10 bolt into deformation. If you have ones thats snapped off and the threaded part won't come out it has been cross threaded.

The 2X 16mm blots are torqued up to 40NM + 1/4 turn.

This additional 1/4 turn streches the bolt

The 2X 13mm bolts are torqued up to 20NM + 1/4 turn