ANOTHER G56 crossmember with sheared bolts! - Dodge Cummins Diesel Forum
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post #1 of 6 (permalink) Old 06-19-2017, 04:12 PM Thread Starter
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ANOTHER G56 crossmember with sheared bolts!

I was under my truck and noticed two partial bolts hanging out on the crossmember. I took a closer look and noticed that one bolts had sheared off and one had backed out on the transmission side. After drilling and attempting to extract the bolt (and failing horribly) I ended up breaking an extractor tip inside. I'm currently out of ideas to remove the bolt. Has anyone had any luck using a dremel bit/rescue bit to drill past the extractor bit and remove a bolt? The two outside holes are from the stock bolts and the two inside holes are from someone else attempting to do fix the issue before.
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post #2 of 6 (permalink) Old 06-19-2017, 07:44 PM
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Have access to a mig welder? I'd fill it in a bit, slide a nut over the filler metal, burn it in pretty warm and back it out

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post #3 of 6 (permalink) Old 06-19-2017, 07:53 PM Thread Starter
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I was thinking the same thing. But will the heat of the weld warm or make the aluminum weaker?

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post #4 of 6 (permalink) Old 06-19-2017, 08:09 PM
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Doubt it will be anything noticeable. I deal with this A lot on the LS series engines with broken exhayst manifold bolts. Gets them out about every single time

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post #5 of 6 (permalink) Old 06-19-2017, 08:11 PM Thread Starter
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I might just pick up a little welder from harbor freight and give that a shot. That'll probably save me a lot of hours grinding away and drilling.

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post #6 of 6 (permalink) Old 06-20-2017, 10:03 AM Thread Starter
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A little update. As it turns out, there's was multiple previous attempts that had been done. (More than I thought it seems) and I wasn't able to remove it with the welder. One of the holes from the trying to drill it out was slightly off set. When it was filled (with the welder) in the process of trying to put a nut on it, the offset hole was filled too. This made it impossible to turn out and we ended up making it a temporary fix instead. So we filled in the hole entirely and welded the support plate to the filled in hole(sheared off bolt) and put a bolt on the passenger side bolt hole that was still good. Now I'm looking for the rear housing to repair the temp fix. It seems like there's only one online site that sells them. Has anyone ever replaced this rear extension housing on a g56?


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