Snapped My Banjo

Bugger. Snapped my rear axle\breather banjo. Went to loosen it and before I knew it, the bolt end snapped off. There is about 5mm of rusty breather protruding. Enough to get mole grips on but I don't want to make it worse. There is also enough to weld a nut on. Suggestions please!

drill it out and re tap

and let all the swarf go into the axle? :doh:

weld a nut on the heat from the weld will be localised and assist you to remove it

Animal88 said:

weld a nut on the heat from the weld will be localised and assist you to remove it

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+1 should work, moles can but no going back if they bugger the thread and squash the tube, but then a welded nut could still shear the remainder!

The Mad Hat Man said:

and let all the swarf go into the axle? :doh:

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well id be changing the diff oil after wards so would be ok

Drill into it, then use a bolt extractor in the hole

Why not just use the mole grips.?!

You might find a good soaking in penetrating fluid and the mole grips will work. Its probably just gunked up with dirt and whatnot

Landyfox said:

Why not just use the mole grips.?!

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I'm worried about collapsing the banjo (with it being hollow and making the situation worse - at least there is something to weld onto at the moment (I don't weld of course).

It looks like a salvageable situation at the moment. If I bugger it up further I think it's going to get expensive. I don't see how I can drill it out and be sure I can get all the swarf out.

I just wanted to see what ideas people had.

EDIT: It never occurred to me it might snap, I was only using a little ring 14mm spanner. I had already sprayed the penetrating fluid, but only gave it about 10 mins.

Braise a nut on and penetrating fluid

sp00k said:

I'm worried about collapsing the banjo (with it being hollow and making the situation worse - at least there is something to weld onto at the moment (I don't weld of course).

It looks like a salvageable situation at the moment. If I bugger it up further I think it's going to get expensive. I don't see how I can drill it out and be sure I can get all the swarf out.

I just wanted to see what ideas people had.

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put a nail or similar down bano to stop it crushing first

jamesmartin said:

put a nail or similar down bano to stop it crushing first

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Good plan. The diff is very well painted. I think it's probably got paint sealing in the threads\bolt. I was just going to scrape around that as best I can with a nail. Is there a more effective method?

mole grips is best plus heat if needed

can't you push the tube over the stump and glue it on

trax said:

can't you push the tube over the stump and glue it on

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Cheater - you got that straight out of the work shop manual

On snapped calliper bleed nipples I hammer a torx bit into the hole in the centre then just wind it out. Sometimes need to drill the hole out a little but it will normally go. The same principal should work on this.

Mark

If you're doing any metalworking put grease on your drill or tap as that will help catch (some of) the swarf. This is recommended in some of Gwyn Lewis's materials
2 x Land Rover Defender Td5 PUMA axle Breather Fittings And M12 Tap wading kit | eBay and he must know what he's doing.

It's hollow in it?
Can't you just use an easyout or bash a torx bit in?

daveo26 said:

It's hollow in it?
Can't you just snap the end of an easyout off in it then take the whole axle to an engineering firm to get it removed by a spark eroder or bash a torx bit in?

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There you go I think that may have been what you meant