I broke zerk fitting... :(

[Mike_The_Grad]

So I broke a brand new zerk fitting off in the brand new control arm shaft bushing I just spent a few hours working on. 1972 c10 passenger side lower control arm shaft bushing, the front one. MOOG kit #6147. So after a little reading online I learned of a tool called a grease fitting tool. Kinda looks like a valve stem tool for bikes/motorcycles. It can install,remove,chase threads,etc. So I went and found one. $10 at oreillys. Well, it didnt work to remove the broken off zerk. Oh yeah, it broke off flush with the end of the bushing. So nothing to grab onto. Anyways, I found a couple of spiral flutes extractors in my tool box. Seemed to be the right size. At first it looked like it might work. Then SNAP. Broke the extractor tip off in the bushing also.
This is day 2 of replacing all the control arm shafts on my c10. I still have the drivers side upper to do. The other 3 are complete, well except the zerk fitting issue. It's the first time it's happened to me. You know, " one more turn couldn't hurt." Lol.
My question probably has an obvious answer. How am I going to get the broken zerk out? I dont want to leave it because you know, greasing and all. And I REALLY DON'T WANT TO TAKE IT BACK OFF. Can i just spin out the bushing and replace it with a new one without dropping the control arm and taking the other bushing out? Or do I have to disassemble the whole thing and remove the broken pieces and then put it all back together? I seen that Brothers is now selling the bushings individually which is less expensive than an entire new moog kit.

Help is appreciated, but anything other is expected. Lol. J/K. Thanks to all those that do offer help. Its what keeps this site worth visting.

[notsolo]

I think removing the Cap is the way to go, shaft will probably move. Might try a jack under it to stablize and a metal shim, or block in between to keep it centered. Tap the extractor tip out with a punch, drill out the zerk center , see if the rest comes out....Good luck.

[weq92f]

.
You could get lucky with left hand twist drill bits and some gentle heat.

Otherwise I think you're gonna be taking the cap off as notsolo says.

Good luck with it.

-klb

[Mike_The_Grad]

Thanks for the input. I would much rather go with the cap removal VS. The entire shaft. It's an unwieldy effort controlling the control arm movement.

[mike1971c10]

There is another you might try. I bought a Lincoln easy out and tap. Part number 66953 and it worked out fine. I tried to up load a picture but it's still trying to load.
mike

[toolboxchev]

Drill and square easy out. I had the same thing happen on the front end in a different location. Its doable.

[HO455]

I too would just block the shaft and remove the end cap and bushing. Then use a punch to drive the broken extractor out from the inside and drill the majority of the zerk out. Retry with an extractor or left handed drill bit. If it still refuses to come out then locate the next over size zerk and drill and tap the hole for the larger size zerk. Reassemble!
Good luck

[Mike_The_Grad]

Success!! I managed to remove the broken zerk with a combination of left hand drill bit and extractor. I first got the broken extractor tip removed by turning it out with needle nose pliers clockwise(imagine that.) Then I burned up the tip on the left hand drill bit so I switched to a #30 drill bit And that got me through the zerk. A #04 screw extractor with a small crescent finished off the job. Cool thing was because the zerk was threaded in so far, the replacement one I had went right in no problem with about a half turn more to seat it. Didn't want to press my luck.

[Steeveedee]

Nothing like success. It sure beat tearing a bunch of stuff apart to get that piece out.

[toolboxchev]

Another Mass Transit Passenger Thwarted!

Glad to see you Got her Done, We are who we are for a reason.

[HO455]

Congratulations! Patience and determination the two best tools in the box.

[lutronjim]

Probably overkill but a friend told me long ago to get a 'needle' attachment for the end of the grease gun and 'shoot' a bunch of grease in to 'flush' out any shavings or scrap.

[69GMC2004]

Glad to hear you got it out. If it happens again in the future the best tool I have found to remove them is a triangle file. Tap the file into the fitting gently then turn, usually comes out with very little effort. I've have better luck with a triangle file than any of my fancy screw extractors (spiral and square) on grease fittings.

[Mike_The_Grad]

I'm glad I greased the inside of the end caps before assembly. I was able to grab my dental picks and scrape out the shavings. The benefits of having a girlfriend who is a dental assistant. That's a good idea about the triangle file. Never thought about that. Thanks.