both brake caliper bolts broke at head

[BillBaker]

I was preparing to change over my front pads and rotors due to a sudden metal grinding noise with no indication from squealers. Soaked bolts with some pb blaster. Both bolts broke off at the head and my guess is they were over-torqued by a shop about 5 years ago. I've searched here with no results on the issue.

Compressed the piston enough to get the outer pad off for some more clearance. The sliders will not fully compress back into the calipers enough (feels like they are bottomed out?) to get more clearance as I would just have used a sawzall to cut the bolts but the issue now is I need enough length on the bolt left to be able to extract the remaining bolt in there and second my sawzall blade is too tall to fit in the cramped area.

Anyone have a bright idea that doesn't involved a stick of dynamite or a blowtorch??

 

[GAmes]

Have you given any thought to new ball joints lately?

 

[BillBaker]

Have you given any thought to new ball joints lately?

No, why do you say that? Mine (Moog currently, will upgrade in the near future as I want the best available) aren't that old and were checked a few months back while up on a lift and appeared to be fine (very slight up-down movement using a HD prybar.

 

[GAmes]

My bright idea is to remove the entire spindle assy, which could possibly render your existing ball joints as unusable.

 

[AHutson]

I had this happen with 2001 not long ago, except mine broke inside the bracket that the caliper bolts to. I ended up just getting new bolts and a new bracket at napa. If I remember right it was $20-$25 total for the parts. I don't remember off hand if taking that bracket loose will let you get the whole caliper off the disc or not but might try that. There is a lot of torque on those bolts so get a big breaker bar. Might also look at getting a can of K&W Knocker Loose, I really like it over anything else I have used for a penetrating oil.

 

[BillBaker]

My bright idea is to remove the entire spindle assy, which could possibly render your existing ball joints as unusable.

That's a good suggestion/option. Hopefully won't have to go that route.

 

[BillBaker]

I had this happen with 2001 not long ago, except mine broke inside the bracket that the caliper bolts to. I ended up just getting new bolts and a new bracket at napa. If I remember right it was $20-$25 total for the parts. I don't remember off hand if taking that bracket loose will let you get the whole caliper off the disc or not but might try that. There is a lot of torque on those bolts so get a big breaker bar. Might also look at getting a can of K&W Knocker Loose, I really like it over anything else I have used for a penetrating oil.

Ok... yes the problem is the bolts broke right at the head so the rest of the bolt is running through the caliper into the bracket which makes the caliper un-removable. This means I'll have to possibly cut the bolts leaving 1/4" (give or take) sticking out to try and remove the remaining bolt in the bracket and salvage the bracket I hope. Think I know my options now..

 

[GReed]

Get some Kroil and soak the threads for a day or two. Maybe you can get a thin vise grip on it.

 

[FHerault]

Could you use a jigsaw with a good metal blade (less tall than a sawzall blade) and patience tu cut the slider (good idea to replace it and they are not expensive) and the bolt at once, near the caliper at the left ? It would give you more room on the bolt to use good vise grips (and Kroil or heat and cold or whatever that could help you unbolt it).

 

[mwilson]

Remove the caliper bracket and caliper as an assembly, then slide the caliper off and deal with the bolts.

 

[FHerault]

Remove the caliper bracket and caliper as an assembly, then slide the caliper off and deal with the bolts.

I thought he has ever done that but the problem was with the bolts that secure the caliper on the bracket (happy twin pistons caliper owners !) But sure it will be much more easy to deal with the bolts with the assembly on a vice than on the truck.

 

[BillBaker]

After 20 yrs and 275,000+ miles I'm giving in and getting a set of EGR calipers.. once I get the other set off..

 

[EDankievitch]

There are two bolts that hold the caliper mounting bracket to the knuckle. granted they will be tight and loctighted but I'dremove them and work on everything on the bench.

 

[Chief USA]

After 20 yrs and 275,000+ miles I'm giving in and getting a set of EGR calipers.. once I get the other set off..

You might want to take a look at Centric Brakes. They make a real nice caliper package that includes pads, hardware, and rubber pieces. I am ordering a front and rear set for my truck from Rockauto.com. You can go onto Centric Brakes website and look up the correct part #'s to verify you have the right parts from Rockauto. I am planning on replacing all of my calipers, rotors, and brake hoses. My brakes are intermittently hanging up on various wheels on both my truck and the wifes. Be sure to carefully bleed the brake system BEFORE you install any new calipers and hoses so you don't bleed all of the crap that may be in your brake system depending upon how long it has been since the brake fluid was replaced.

 

[jimpeg1]

I just replaced the calipers on my 97 2WD. FYI, Raybestos makes new calipers (not refurbished) and dont require a core. So just cut away on that old caliper if that is what is needed

 

[BillBaker]

I did resolve the removal of the old calipers (was only the left hand side) that both bolt heads broke off. After removing the brake reservoir cap to remove fluid I was able to compress the caliper piston which gave me enough room to also get the outside brake pad off. After searching for a shorter sawsall blade I was able to get in there and cut the caliper bolts with leaving enough there to potentially grab it with some vice grips and with the help of Kroil they both came out with ease.

 

[BillBaker]

You might want to take a look at Centric Brakes. They make a real nice caliper package that includes pads, hardware, and rubber pieces. I am ordering a front and rear set for my truck from Rockauto.com. You can go onto Centric Brakes website and look up the correct part #'s to verify you have the right parts from Rockauto. I am planning on replacing all of my calipers, rotors, and brake hoses. My brakes are intermittently hanging up on various wheels on both my truck and the wifes. Be sure to carefully bleed the brake system BEFORE you install any new calipers and hoses so you don't bleed all of the crap that may be in your brake system depending upon how long it has been since the brake fluid was replaced.

I already got the EGR calipers on and yeah it's about that time to do replacement of front end parts. This was a quick fix for a DD truck. I have the same plans to replace the rotors, hubs, and ball joints all in one shot next I hope. I'm waiting on EMF ball joints that I hear good things about. The have the upper already and EMF says they'll have the lower sometime in 2018.. so we'll see if they do.