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What to do now? Throughly screwed? 200 1992

posted by  bjinSeattle on  Tue Dec 31 14:24 CST 2002
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'92 240. I may be the only one to ever do this. I screwed up royal and busted off the right rear upper caliper bolt, sheared it off right where it enters the axle boss. I tried to get the good old grade 8 bolt out by removing the coil spring and going at it from the back side. Bad move. Impossible to get it really straight. Too late realized that I should have gone at it from the wheel side after freeing up the backing plate. At this point I have a very slightly egged hole that probably removed the threads on the back side one side. Tried an ez-out but no go, the hole is too big and the next size up just graps the axle boss. At this point I'm ready to drill and tap the hole and replace the metric bolt with a 7/16 standard because it is slightly smaller than the next size metric equivalent. I'll have to bolt up the caliper and drill a clearance for the oversize replacement. This bothers me big time because I'd have to get everything straight and I'd be trying to do it freehand and would probably get the hole off center. Any ideas other than buy a used rear axle? I'm ready to haul the thing off to my independent and chalk it up to getting in over my head. TIA, bj.
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