METHOD 1: WD40

How to remove a broken bolt

If you try this method first, you may not even need to learn how to get a snapped bolt out. If you’re looking at a rusty bolt, or something as notoriously difficult as exhaust studs and nuts; don’t even grab a spanner. Simply spray them with WD40 and leave this to soak overnight if you can afford the time.

When you return to attempt removing the fastener, reach for a six-point socket rather than a twelve point. The larger, flat sides offer more contact area than a twelve-point socket which lessens the chance of rounding your nut or bolt.

METHOD 2: Bolt Extractors

How to remove a rounded bolt

Sometimes a nut or bolt will be so corroded or rounded that even a six-point socket will slip and round it further. In this case, it’s time to reach for the bolt extractor set.

If you haven’t applied WD40 to the bolt yet; now is the time to do it. Then grab an extractor the same size as your bolt head or nut. If it’s SUPER rounded, just grab one which appears to be the closest fit.

Now simply pop the extractor onto your ratchet and use it as you would a normal socket. Your extractor will bite harder into the fastener as you apply more force to it. If you have trouble getting the extractor to bite in; try tapping it on with a hammer.

METHOD 3:

How to remove a seized nut

If you’re still not having a win, it’s time to try a nut splitter. This tool is ideal for nuts which absolutely will not budge.

Slip it over the nut and hold the body of the tool steady with a spanner. If you have an impact wrench, you can use this to tighten the screw on your nut splitter. Otherwise, a ratchet works just fine.

Split the nut right down to the thread, being careful not to damage the thread. If the nut still won’t budge, you can rotate the nut splitter 180 degrees and split it again. Now the nut will come away in two halves.

METHOD 4:

How to remove a snapped bolt

To remove broken bolts, you’ll need a set of screw extractors. Soak the remainder of the snapped bolt with a squirt of WD40, then grab your centre punch and mark precisely the centre of the snapped stud or bolt.

Select a screw extractor from your kit to closely match the size of your snapped bolt.

Now choose a small drill bit, but not so small that it might snap easily and cause more problems. Lubricate the bit with an occasional squirt of WD40 and drill steadily.

Work your way through larger drill bits until the hole is deep and wide enough for the screw extractor to bite into.

A tap with the hammer will seat the screw extractor into the bolt. Now as you turn the screw extractor anti-clockwise it will bite harder into the snapped bolt to make for a successful extraction.

How to repair a thread

Now that you know how to get a snapped bolt out, and you have removed the broken bolts or nuts; you may need to repair the thread before replacing the fastener. Grab your tap and die set and compare your existing bolt or stud against a tap to find the right diameter. Then closely inspect the threads to ensure they interlock with the tap tightly; this will confirm the correct pitch.

Then, once again with a little WD40 for lubrication, gently run the tap through an internal thread, or the die over an external thread.