Outer Limits 4x4 Board

I have found one of the bolts securing the Beudesert Exhuast has snapped off at the head and there is a little freeplay.

It looks like it is rubbing against the oil return line. (???)

I have taken it to 2 mechanics and they both told me that it can't be tapped out due to where it is a muffler place told me not to worry about it.

Can anyone please give me some suggestions on how to get the thread out, so I secure the bracket with a new bolt.

The pic clearly shows the offending bolt. The discolouration was caused by the mechanic spraying it with lanotec.

I was just going to hacksaw it off, but just not sure how much support this bracket gives the system. Can anyone shed light on this.

It is on a 2003 GU Patrol.

Drill it and easy out if you have the room.

Weld another bolt onto it, and wind it out.

Put a clamp on the bolt hold just to the right and forget about it.

call threadtech 0418885463 1300847323 they will come out and fix it. i have used them before.

have you tried unscrewing it? If it has broken from vibration it will proberly just unscrew with a scriber.

I have fitted beau ex before on td42 and not seen a bracket there. I know yours is not a td42, but do you think it needs the extra bracket? Sometimes a component thats too ridgid will fatigue.

Thanks guys for the help.

Looks like I may just cut it off and use the clamp suggestion. So simple, thanks.

As for the need of this additonal support, I am just concerned about the weight of the dump pipe hanging straight off the turbo, with no support. But if this in not on the TD42, then it should be ok.....shouldn't it ?!?!?

Looks like you could modify the bracket to mount to the other threaded hole if necessary, but if you have the room it shouldn't be too hard to remove the broken bolt. I would try using a punch first (you may have to use a cold chisel to make a small shoulder to punch against), it might come out easily. If not, drill and use a parallel easy out. I like to drill right through and spray some penetrating oil in before fitting the easy out. Best to use good quality easy outs.

If it were me I'd remove the broken bolt and add an additional bracket so both bolt holes were used.

It looks like the bolt broke off due to not being tight enough and allowing the bracket to move.

Check the exahust is free to move at all mounting points after this support.

Remove the broken bolt using a reverse drill bit (available from specialised tool shops)

I'm guessing the support is there for a reason. If it's like the cruiser it would be hard to get a drill in there. If the above ideas haven't worked, I'd also try putting a groove in the top of the broken section with the fine cutting blade on a dreml, small flat bladed screwdriver could then unscrew it (once the head is off a load bearing bolt it's normally easier to unscrew). Once unscrewed you don't need to tapp anything out, just fit new bolt.

Good Luck.