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Old 11-16-2014, 09:03 AM   #1
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1999 Rexhall Seat Belt issue

I have a 1999 Rexhall Aerbus, built on a Ford chassis, with a V-10 power plant.

I have a broken bolt in the chassis by driver side door, that I cannot get out due to rust. I have broken an extractor tool in it as well. This bolt is used to secure the seat belt retractor.

Any ideas how to fix my problem? My local RV service shop is NOT equipped to fix this issue.

Thanks ,

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Old 11-16-2014, 09:11 AM   #2
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Originally Posted by JBHERMANN View Post
I have a broken bolt in the chassis by driver side door, that I cannot get out due to rust. I have broken an extractor tool in it as well.
Any ideas how to fix my problem?
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Old 11-17-2014, 09:23 AM   #3
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I prefer this type extractor Vermont American 21872 Straight Flute Screw Extractor Set, Red, 5-Piece - Tap And Die Sets - Amazon.com instead of the screw type. Since you can't use heat without damaging the wall you will need to use some penetrating oil and a lot of patience. I like using PB Blaster, spray bolt with it tap the bolt several time tap bolt again, walk away for awhile. Do the above several times before trying to remove the bolt. If the bolt still won't move do the spray and tap again, eventually the lube will penetrate the the threads and break the rust bond. Another way would be to drill out the bolt with a drill without damaging the threads. Use a small metal cutting blade or a small file to cut a relief cut all the way through the threads. Once the relief cut it made use a small chisel collapse the bolt. You may need to make two relief cuts to get the bolt out.

Chuck & Teri, 1999 35 ft. Dolphin 5350, F53 Chassis with tag axle, Chassis build date 1/99 in Mexico, Banks System, Trans Command, Air Lift Air Bags on rear, Koni Shocks, Blue OX TruCenter, TigerTrak track bars front and rear, Roadmaster 1-3/4" rear auxiliary sway bar, 2013 VW Passat TDI SEL Premium, 1994 36 ft. Avion 5th Wheel. FMCA #F430129
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Old 11-17-2014, 09:47 AM   #4
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Thx for the reply, much appreciated.

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Old 11-17-2014, 09:48 AM   #5
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Thx for the reply, much appreciated.

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Old 11-17-2014, 10:21 AM   #6
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If the hardened extractor is broken off in the hole drilled into the broken bolt, it will be very difficult to use a drill. You'll need to remove the broken off extractor before doing any drilling or the drill bit will either break or wander off the hardened steel and drill into the softer steel threads or bolt. I had the same situation in a broken water pump bolt many, many years ago. Try using a punch and a hammer to remove the broken extractor before doing any more drilling. Once the hole is open, you can spray with PB blaster and drill the hole out using larger and larger drill bits until you can remove the remains of the bolt.


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