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I have another prospect for removing the broken bolt that doesn't involve an easy-out, since you seem to be saying that a little of it is sticking out. Also, once you get the ball joint mounting plate off, this will be easier. As indicated in other posts, get some good penetrating oil into the bolt and all around the mounting plate. Some light tapping on a cold chisel all around the edges of the plate will help loosen it up, too. Have no fear, it will pop off eventually. A wise man (old Volvo expert Don Thibault, actually) once advised me to keep in mind that all of the gear in that part of the car is intended to have a quarter of the weight of the vehicle bouncing on it all the time, so you don't have to be too concerned about whacking it with a hammer once in a while. My philosophy is that you'll never get discouraged by a job on the car if you always bear in mind that it is within your power to hit it with a hammer.
If you have a dremel, use a reinforced cutoff wheel to cut as deep a slot in the end of the bolt as you can. If not, a hacksaw will do, but the dremel has the added attraction of heating the bolt at the same time. Then try to get it out with a flathead screwdriver. If you have screwdriver bits for a socket set, this will help, but if not, I find that a pair of channellocks on a good sized screwdriver does the trick, too.
If this doesn't work, then the slot you've cut will help you guide the drill bit to make the hole for the easy-out.
Good luck,
-EdM.
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'90 240DL Wagon 'Lola' -- '72 1800ES 'Galadriel'
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