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Old 06-22-2010, 05:43 AM   #6
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Join Date: Nov 2005
Location: Florida
Posts: 529
I've had it happen twice and...

... was able to successfully remove the broken bolt by drilling it out.
I use successively larger LEFT-HAND drill bits.
Grainger has a nice set. They are expensive, though.
The trick is to start completely centered, so you'll need to carefully center-punch the broken bolt. You may need to file a flat spot if it's crooked.
Also, soak overnight with PB Blaster.
Once you start to see the threads, use a sharp pick and pick out the remnants.
Sometimes the action of the PB Blaster and the use of the left-handed bits will remove the broken bolt.
Happy Boxstering,
Pedro
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