Reebs

Really appreciate all the responses you guys have given me. Great resource for people like me who step into a bees nest. Seems like several think I can still back this thing out so I guess that is my next best step. My biggest fear is I need a steady hand to keep that drill bit centered because I don't want to hit the threads and since I can't see the end point of what I am drilling I may not know where I am (if that makes any sense). The way I see it, I will need to apply a fair amount of forward force even with the left handed bit to bite but at some point I will need to start pulling back to see if it will back out. Again, not being able to see it makes this challenging (for me).

Thanks for the replies! Toodeep: I am not sure the pick (unless I am not understanding what that tool is) would be able to get it because I can reach it with the 1/8 extractor and have no luck). Would a pick be any different? Again, I have pushed this broken bolt stud so far down the thread, I can't even see it without a flashlight so I don't even know whats happening at the contact point). That magnet idea is a great idea- wish I had posted before I tried to drill it out- that might have worked! Don't think I can get a magnet to it now?! By the way, I couldn't help but notice your screen name is very appropriate for my situation! Fishfiles: yes- the broken stud is still in the threads pretty far toward the differential. Although between the check bolt shaft and the left wall of the differential that's pretty thick, but its hard to know how far in it is. I don't have enough experience to know what is inside the differential, but I never thought of that...I suppose it is possible the broken shaft hit the "other side" before it can fall through?? Regardless, what my best plan here? Leave well enough alone, or continue to try and get this out? The downside to leaving it there is the oil check level will never function properly, but if that's the worst that can happen am I better off leaving this be vs taken things apart from here (unless you still think I can back this thing out somehow? I am including a few photos showing my situation. These photos are taken after I broke the head off the bolt but before I tried to drill it out. The stud is way far down the shaft now from what these photos show. So much so, that I can completely screw in another "new" 8mm check bolt.

I could use some advice! I made a rookie mistake that should have been so simple and never been an issue to begin with and hopefully I have not screwed myself! I have a 2014 Honda Rancher- 2x4. I was changing the oil in the rear differential two Saturday's ago. All was going fine until the very end when I was replacing the check bolt after adding new oil and closing everything back up to finish. Normally I just tighten the check bolt down to what feels right but this time I decided to use my torque wrench as the manual suggests (old school style torque wrench I believe called a "beam style"). I hand tightened the bolt 90% of the way. The ft pounds required were so low at 9lbs and I just kept turning the torque wrench thinking it wasn't registering on the scale because I hadn't tightened it down enough. I was surprised that it was taking so many 1/2 turns, but I didn't realize the bolt was already as tight as it was going to get and the torque wrench was never going to register because it was such low torque at 9lbs the wrench scale wasn't picking it up and before I knew I torqued the 8mm head right off the check bolt! So I just created a much bigger problem when I should have been done with the job. I am probably the first to ever do this with a check bolt! So, yesterday I went to make the repair and proceeded to take the tire off and try and drill out the bolt. Next mistake I made was not trying a left handed drill bit first- huge mistake because it probably would have worked. My plan was to just drill it out clockwise about 1/3 of the way into the sheared bolt- stick an extractor in and back it out. Instead, when I started drilling, I thought I was drilling it successfully because my drill bit was going in...what was really happening was I was just turning the sheared bolt further toward the center of the rear differential (so the stud was not in there very tight at all since the head broke). Now that sheared bolt is so far in, I can't get it- you can't even see it without a flashlight (in fact I am shocked I didn't push it all the way out). Any suggestions on what I should do? The good news is I changed the oil, the level is right because oil flowed through the check bolt hole before the mistake so I know I am good for 2 years. The problem is, do you think that bolt will work itself into the rear differential? If it does, how serious would that be? I could just leave it in there (I did have a back-up check bolt and I put that in and it threaded in fine (and I went out and bought a new "click type" torque wrench and if I had that the first time I'd have no issues at all!). I can still do future rear diff oil changes I suppose, just won't be able to see the oil flow through the check bolt hole if that stud stays in there forever. Do I try and take apart the rear differential to get this out or just leave it be and move on with life? I am just afraid of what damage will occur if it "falls" in and also afraid of doing way more work than necessary if I try and get the stud out by taking it apart. Advice for me? Thanks!