Snapped My Banjo

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Tried the torx bit, but before I could get enough torque into it, it started rotating. Had a few goes at that. Finally moved onto the mole grips. After a few goes, the remaining banjo fractured, so I now have a few mm of half of one left sticking out :(

I can't get in over the top to see it, but I presume that there is still a good part of it left inside.

Before breaking it, I took it to my local friendly landy mechanic. He took one look at it and said it would never come out - he was right :) I asked if there was anything he could do with it and he said the only way to sort it was to drop the a-frame so that the axle could be rotated into a position where it could be drilled. He said he would not be able to get enough force onto the drill from above, which was why it needed to be rotated.

From below, it looks to me like it would be possible to cut an access panel in the floor of the tub to access it from above.
 
sp00k said:
Tried the torx bit, but before I could get enough torque into it, it started rotating. Had a few goes at that. Finally moved onto the mole grips. After a few goes, the remaining banjo fractured, so I now have a few mm of half of one left sticking out :(

I can't get in over the top to see it, but I presume that there is still a good part of it left inside.

Before breaking it, I took it to my local friendly landy mechanic. He took one look at it and said it would never come out - he was right :) I asked if there was anything he could do with it and he said the only way to sort it was to drop the a-frame so that the axle could be rotated into a position where it could be drilled. He said he would not be able to get enough force onto the drill from above, which was why it needed to be rotated.

From below, it looks to me like it would be possible to cut an access panel in the floor of the tub to access it from above.
Click to expand...

my glue idea isn't looking too bad now is it? :D :p
 
isn't the banjo brass btw?

did you try heating it up and seeing it it'll move?

works a treat on brass screws
 
trax said:
isn't the banjo brass btw?
Click to expand...

Seems to be mild steel/cheese

did you try heating it up and seeing it it'll move?
Click to expand...

No. I did not have the nerve given that the axle is full of oil and the diesel tank is directly above it. Given the way my luck's been going, it did not seem worth the risk.

works a treat on brass screws
Click to expand...

The banjo part itself is probably brass, but this is the hollow bolt that goes through it.
 
sp00k said:
Before breaking it, I took it to my local friendly landy mechanic. He took one look at it and said it would never come out - he was right :) I asked if there was anything he could do with it and he said the only way to sort it was to drop the a-frame so that the axle could be rotated into a position where it could be drilled. He said he would not be able to get enough force onto the drill from above, which was why it needed to be rotated.
Click to expand...


bollix - just use a right angle drill :doh:. any decent mekanik should have one.
 
The Mad Hat Man said:
bollix - just use a right angle drill :doh:. any decent mekanik should have one.
Click to expand...

Thanks for all your help guys. Time for plan C!

That's what I said, but he said he would not be able to get enough force on it. Also, I don't have air tools but I would have thought an air drill would be small enough to get in. It's only rear exhaust section that's in the way.

So, if I have a go myself. I know the procedure for a solid bolt (mark the centre and drill it) but what about for a hollow bolt like this? Cut if off level and drill the bolt out in one operation or with increasing bit sizes and then retap?

In terms of the axle, is it just the half shaft in that area - is it possible to remove the half shaft and clean out the axle from one side or is it too narrow, or would warming the oil and changing it be enough.
 
Grease the drill and the tap and you won't get much in there if you are careful and like I said before get a left handed drill bit and you may find it bites in and winds the remnants out when it gets hot from drilling
 
Jam1 said:
There you go I think that may have been what you meant ;)
Click to expand...

Yeah I was just trying to offer some possibly constructive suggestions to this poor bloke because we have all been there staring wild eyed at something that's all gone tits up.
It's difficult without being there to know what to suggest.
Iv used easy outs in the past with much caution and some success :scratching_chin:
 
if your going to drill it out, most of the swarf will come out with the drill and only a minischool amount will go into the axle. if its steel like you said, after changing the oil, glue a magnet very near the drain plug and after a while, knock of the magnet and wipe out the swarf. i think your being overly worried about a couple of bits of swarf. there's probably more steel in the diff thats worn off your half shafts!
 
daveo26 said:
Yeah I was just trying to offer some possibly constructive suggestions to this poor bloke because we have all been there staring wild eyed at something that's all gone tits up.
It's difficult without being there to know what to suggest.
Iv used easy outs in the past with much caution and some success :scratching_chin:
Click to expand...

I know mate.
The bigger sizes aren't as bad but definitely wouldn't recommend the smaller ones on an old fixings from painful experience :(
 
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