Managed to shear off two of the many bolts holding the front differential cover while changing out the front axle oil. I was using a torque wrench set at 30 ft/lbs. The torque wrench failed to "click" but tested fine before and after against another wrench. Looking at tbe bolts recently re-installed by the dealership, they had lock tight on them. Should they have lock tight on them? The bolts sheared approximately 3/8" from the head. Any mechanics out there?

 

I can't remember if mine had Locktite or not, but it wouldn't hurt; but thats not what sheared them.

 

Yes I think they had blue locktite from the factory.

Are the bolts next to each other. If not the new reusable gasket might seal it fine with a few missing bolts especially if they are up top.

Other than that you will need to use an extracting tool (easy-out). You drill as best you can into the center of the boken stud, being careful not to go too deep. Take one of the good bolts out and use a toothpick an a black marker to gauge the depth.

You drill the stud and insert the easy-out, turning it counter clockwise. It shouldn't be too tight becaause once the bolt head breaks off the pressure on the threads is released. Go to Pep Boys or a agood auto store and buy expensive good quality set of easy out or just the size you need.

 

I don't recall ever seeing Loctite on those bolts, nor have I ever used it there. The broken bolts should not be too hard to remove, as the tension is gone after the head snaps off, as long as they are not bottomed in the hole. You may even be able to spin them out with a small pick or such. Another miracle tool you can try is a left-handed drill bit which often spins the broken bolt right out as it drills.

 

An easy out is your answer at this point, Hoot's right don't skimp on this tool. You will not respect yourself in the morning, just take your time and you can get them out pretty easy. I say that... it's always easy a thousand miles away. Good luck.
How many miles do you have on your 03, can you get some good pics of the bolts and where they sheared?

 

Got the truck back from the dealer last night. They charged me an hours labor to remove the bolts which may or may not be too bad considering I did not have to go buy the easy outs. One at the top sheared and one at the bottom.

The removal of the sheared bolts was the cheap part. I had them replace the differential oils front and back and do an oil change, $390 later the truck is just as it was with clean oil.

Many thanks to all.

 

I will try to post a photo

 

You should have gone to Sears and got their screw extractors. They have 2 types, one that looks like a nut that you place over the screw and then the Easyout type. The one that looks like a nut works real good and is worth having in the tool box.
I hope the $390 was worht it because that;s alot of money for what they did. for that price they should have done the Tranny and Differential also

 

Good synthetic lube ain't cheap. About $10 a bottle. I put a Mag-Hytec cover on my rear. Figure $70 for the rear and $30 for the front, already the DIY for me was is $100 just in lube.

$390 to take out two broken bolts and do the rest of the labor, front and back is a little high but not a surprise.