I have a 1997 Town and Country 3.8 which has the crankshaft pulley bolt broken off inside the metal shaft that the pulley slides onto. The end of the bolt is about 1" inside. I am trying to slowly drill it out but am not sure how long the bolt is or if there is room behind where the bolt seats so I don't drill into and damage the crankshaft.

Is there a space behind the bolt I can safely drill through? Does anyone have any other ideas on how to get it out. The pulley is off and out of the way (not that it made much difference).

Any help is greatly appreciated.

Thanks.

 

Is it cross threaded or did it just break off because of tightening? You're not going to hurt the crankshaft as long as you keep your bit centered. There is about 3/4" of space after the bolt. The whole bolt is about 5 inches I think. Get an extraction kit. It has drill bits and extractors that bite into the drilled hole when you turn them. Use lots of rust penetrant and tap with a hammer intermittently to loosen the threads from each other.

http://www.handsontools.com/Hanson-5...et_p_9139.html

Many parts stores sell these