Snapped allen key head in caliper bolt

[D3GGY]

Originally Posted by Lou Ferrigno

It looks to me as if all that has happened is the Allen Key has snapped off in the recess of the sliding pin.
The sliding pin is not damaged so there should be no drilling or tapping necessary to the pin.
All that is necessary is to get the small piece of Allen Key out, so that a new and better quality Allen Key can then be used.
The suggestions of a magnet, epoxy or tiny drill to retrieve the piece all seem good to me and worth a try

I suspect that if the Allen key has snapped its done it for a reason, the pin is seized solid. 7mm Allen keys generally don’t snap. I am surprised that this went before the thread though as the thread root will be smaller (marginally) Can’t remember if the pin has an 8 or 10mm thread.

[kenny]

I will not be easy drilling either the snapped head or the bolt, they will both be hardened to do their jobs.

[lockstock]

Originally Posted by kenny

I will not be easy drilling either the snapped head or the bolt, they will both be hardened to do their jobs.

It's a good point, car is probably a write off

[D3GGY]

Originally Posted by lockstock

It's a good point, car is probably a write off

LOL

No its not you can get the callipers assembly off if you remove the complete assembly. If you cant drill it out yourself any decent machine shop will be able to do it. At worse its a new calliper.

[kenny]

Originally Posted by lockstock

It's a good point, car is probably a write off

Are new callipers that expensive these days?

[lockstock]

Originally Posted by D3GGY

LOL

No its not you can get the callipers assembly off if you remove the complete assembly. If you cant drill it out yourself any decent machine shop will be able to do it. At worse its a new calliper.

jesus sarcasm is lost on you people haha

[Zebster]

I can't see why anything needs drilling out, nor how you would even drill out the snapped off end of an Allen key.

[lockstock]

Originally Posted by Zebster

I can't see why anything needs drilling out, nor how you would even drill out the snapped off end of an Allen key.

I had to do something similar once. Centre punch the nub. Drill in with a small hardened hss. Then go larger, and larger again. left with a polo.. you can use a hammer and an old flat head or punch to colapse in the edges and it will come out easily. Still the possibiloty to then dislodge the bolt with an impact wrench

The reason being, this will be less work, if it works than removing the whole assembly, and accessing a workshop with a pilar drill to drill out the whole nut and retap the whole....

Having said that, a whole new caliper and carrier don't cost much second hand, so maybe just grind it off, put on a new one and bleed the brakes......

[Zebster]

If you tip it up it might even fall out... Or it might need a few taps with a hammer to loosen it. And then the bolt can be undone with a decent hex wrench. Storm in a teacup!

[S60D5-185]

Hands up, I misinterpreted what I was looking at and should have read it properly. I was wrong!!!!

I thought that the head of the Allen Bolt slider has sheared off hence why I said the slider would need drilling out from the back.

Now that I can see that it is actually the allen key that has sheared in the allen bolt head , that should be way easier to fix.

Apologies to all.