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AC Compressor Bolts Break Off, Why And How To Fix It?

AC Compressor Bolts Break Off, Why And How To Fix It?

When the bolt holding the AC compressor in place breaks while being removed, it is a horrific experience. You might just want to freak out at that point since you have no idea how to fix a bolt that has broken off in a casting.

You should attempt any of the following methods to remove broken AC compressor bolts:

  • Use a kit for extraction.
  • Apply the welding method.
  • Implement penetrating oil.

We’ll cover a variety of tools, methods, and suggestions for removing broken bolts in this post.

Remove Broken Bolts From An AC Compressor

AC Compressor Bolts Break Off, Why And How To Fix It?

We’ve found that some methods are more effective than others for removing bolts. These instructions will show you how to swiftly and simply remove broken bolts:

Utilize An Extraction Tool

The beautiful benefit of misfortune is that it spurs creative ideas and solutions. The extractors should be inserted into the hardware after a pilot hole or other indentation has been drilled into it.

Screw extractors work in this way. You can rotate the extractor so that the bolt will turn out when the edges grab on the pilot hole. This technique typically releases you from a jam and works on bolts that are only slightly jammed.

Taking It Out

If the bolt is not entirely seized, it might be able to move it. If it has a burr, you might be able to get a screwdriver or small chisel behind it and tap the broken piece out with a gentle hammer. If this doesn’t work, spin the shaft by tapping a hole near to the edge with a centre punch.

Extreme care must be taken when using this procedure. You run the danger of breaking the threads or enlarging the head, which will only serve to tighten it further, if it still won’t come out after several tries.

Creating A Head Hole With A Left-Handed Drill Bit

Because drills normally move in a clockwise direction, using this on the sheared-off bolt immediately tightens it. However, if you use a left-handed drill bit and set the drill to reverse, the power applied cuts in the opposite direction, turning the stud out naturally.

The likelihood that the left-hand bit will bite into the bolt and turn it out for you as you drill is high due to pressure, friction, and heat.

Release With A Bolt Extractor

To release the sheared-off bolt, another option is to use a bolt extractor tool.

To release the sheared-off bolt, another option is to use a bolt extractor tool. A damaged bolt is caught by the screw extractor, which has threads that resemble drill bits moving counterclockwise and spins it away from its attachment point.

The worst of these problems with screw extractors is the possibility of a break occurring inside the screw that is being extracted. Due to the exceptionally hard material and inability of drilling through the first screw extractor, the task of removing the first screw is made more difficult.

Drilling Out The Screw

The only other alternative, if none of these fixes work, is to drill out the screw or bolt and retap a new set of treads. A labor-intensive last resort, this.

Advantages And Disadvantages

  • Bolt extractor use is a far more dependable and consistent repair method.
  • Any technician, regardless of skill level, may finish it with the right tools.
  • When there is little space, this might be a better option than pulling the entire engine head.
  • A difficult endeavour could turn into a full nightmare without the proper tools.
  • Cheap drill bits and extractors almost never provide high-quality work.

Utilize The Welding Method

AC Compressor Bolts Break Off, Why And How To Fix It?

This method requires welding experience or the ability to hire someone to do it for you. This tactic assumes you are familiar with welding and have access to a welder.

You must select a MIG welder rather than an arc welder for this job. The latter generates significant amounts of slags, which enter the weld. However, the major objective here is to remove the sheared-off stud, and the first welder will do the job just well.

Getting Rid Of A Sheared-Off Bolt

One of the more efficient ways to solve this is to procure a nut of the same size and solder it over the sheered head of the trapped bolt. The disintegration of the metals is aided by the various fractional expansion rates of the metals brought on by heating and cooling. After it has cooled, pull the freshly welded nut out with a breaker bar.

Repairing A Broken Stud

Start by selecting a nut or flat washer with an inner diameter that is roughly equal to the threaded bolt’s size. Use a welding gun to join the inside of the nut to the broken bolt top after attaching the flat washer, nut, or both to the bolt.

Next, use a wrench to separate the nut and bolt. For example, titanium alloy bolts—which are frequently used in turbocharged engines—need much more attention and heat to fuse.

Additionally, using a welding head to reach low-vision, challenging places has its own set of challenges. Not all problems can be solved by welding, to say the least. Not every solution works in every situation, like other remedies.

Advantages And Disadvantages

  • Applying the right techniques can make welding quick and reasonably priced.
  • It necessitates a solid knowledge of heat transfer and welding.
  • Due to equipment setup, heating, cooling, and numerous efforts, it takes time.
  • Modern engines are made of a variety of metals, making welding them together extremely difficult.

Employ Penetrating Oil

Strong penetrants provide an unrivalled way to get rusted and corroded things to release. For years, stubborn metal pieces have been successfully removed without the possible risks of using heat by using penetrating oil. Penetrating oil provides lubrication and corrosion protection that heat cannot while heating requires regular attention.

Heat and penetrating oils should be used in successions as opposed to simultaneously. Be careful to remove any oil from the part’s surface and the surrounding area before utilising heat or an open flame.

After a difficult task, properly cool the part before applying the penetrant. When rust or corrosion slows you down, use a high-quality penetrating oil rather of a torch. You can complete challenging jobs more safely and successfully than by employing heat.

How Can A Broken Aluminum Bolt Be Removed?

The top of the bolt should be completely flattened out using a metal file. You should place a bolt removal bit on this flat surface.

Turn the bit once it has locked into the bolt. By rotating the bit back to the left, the bolt can be twisted and released from the metal.

Can Aluminum Be Heated To Remove The Bolt?

If the nut or bolt still won’t budge, try heating it with a propane flame. Allow the nut or bolt to cool after several minutes of torch heat before proceeding again. When using a torch to warm a connection, be careful to keep all combustible materials distant from the area to avoid starting a fire.

What occurs if the AC compressor malfunctions?

AC Compressor Bolts Break Off, Why And How To Fix It?

When a compressor breaks out, the AC stops functioning. The fans may still be operating, but no cool air will be escaping via the vents. The compressor is such an important component and is so expensive to fix that a homeowner must make a serious decision regarding what to do next.


We hope that this post has helped you understand how to handle your concern about a damaged bolt. You should have a professional evaluate your AC compressor as soon as you can to prevent more damage now that you have practiced the fundamental techniques for removing broken bolts.

AC Compressor Bolts Break Off, Why And How To Fix It?

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