Any suggestions/tips on removing a broken bolt in the secondary drive shaft? (The one that holds the driven clutch on) I was thinking of drilling a small hole in the side of the belly pan and trying a easy out? Also can you use a grade 8 bolt as a replacement or is this a bad idea? (I would prefer not to have to remove the shaft if possible) Thanks.

IMHO the fastest most pain free way is to mig weld a nut onto the broken stub, no sweat if it's broken off flush or even inside the shaft a little, and it'll pop right out.
Works especially good on bolts that have long since been siezed with rust as the deap heat from welding always seems to help break it free.

Rick.
:cool:

It's brokem off about 1/8" inside the shaft!

No sweat at all with a mig welder. How did it break?

I will see if our welder at work wants to give it a try tomorrow if he has time. I was putting the clutch on tonight after working on the sled for 5hrs and it was the last thing to do and I set the brake and gave it just a little more and snap!

same suggestion but i would use a tig welder.Mark

Brought my sled in to work and the welder agreed, not enough to weld too. Too easy to mess us the hole and threads. The bolt is about 1/4" into the hole (from the end of shaft to the bolt is like 1/4" recess). However your idea is a good one and I will keep it in mind for future use.

Yup tig would work even better. Any guy thats a little inventive with the welder can handle that no problem. I've used that technique tons of times on broken exhaust bolts in cylinder heads and have yet to not get one out.
If it's broken off somewhat flat, drilling and an easy out should do what you need.

Use a left hand drill and drill a hole for the easy out. Hopefully the drill will grab and the bolt will screw right out. If not then you have the right size hole for the easy out. I would apply some heat to the shaft before inserting and turning the easy out to make sure you have the best chance. If that dont work buy a new shaft and a torque wrench for next time.