Ok I thought I grenaded my tranny , it has the Getrag and 205 in it. Dropped the entire tranny and t-case and realized that the t-case was loose from the tranny. Started taking it apart and all the nuts were loose and 2 of the studs were sheared off. Ended up that the sleeve between the out put shaft of the tranny and the input of the t-case stripped on the t-case side and the input shaft is ok. So yeah a lot cheaper than I thought. Tonight I was trying to extract the studs from the t-case and broke off the extractor inside the stud. So needless to say I am completely frustrated. Does anyone have any ideas on how to get the studs extracted? Oh yeah, to add insult to injury the only other vehicle we have running as of right now blew a radiator the following day. So I got that fixed today thank God!! All this while trying to pack the house to move into our new house. Can anything else go wrong?

 

Is there anyway you can get something welded to the broken piece? That would give you something to grab and sometimes the heat helps loosen it. Other than that you're going to need some carbide to get through the broken easy-out.

 

Someone on my 4x4 board suggested welding a flat washer to it and keep stacking them up. I might try that tonight. The studs were sheared off flush with the mounting surface.

 

2 of the most important things to do when extracting broken studs.
1 drill as close to center as possible
2 drill all the way through if you can.
drilling all the way through seems to releave pressure.
A broken easy out? that is a lot of work. some times you have to chisel it out. It should break since it is hard and brittle, dont forget the safety glasses.

 

There's 2 methods we use on broken bolts or studs in cast iron (manifold bolts on our John Deeres or anything else for that matter). I believe the 205 case is cast iron and not cast steel (someone correct me if I'm wrong).

Torch whats left of the stud out and run a tap in to clean up whats left.
or
If the broken item is flush or above flush we'll weld a nut onto it and then you can wrench it out. The heat from welding the nut on helps if it siezed in there.


Sorry to hear about the easy out, thats going to take some patience to get that out.

 

Use a left hand drill for drilling, weve had good luck with studs backing out just with drilling.

 

If you can find a machine shop with a EDM drill they should be able to burn them outwith no damage to case, Try to get others out frist, in case you break more extractors.
Clark