Hello all, new S2000 owner here. I bought my car with the infamous TCT rattle, and after just one week I was sick of it. I unbolted the TCT and tore it down, sandblasting the needed parts, and put it back together. However, when I went to torque it down to 9 ft / lbs, one of the bolts on my TCT broke within my head. It's far too stuck in there for me to take vice grips or pliers to , and I don't have access to a welder. What else are my options ? Even after removing the airbox I'm still doubtful there is enough room to stick a drill in there. I was contemplating JB welding another bolt on the end and attempting to turn that out , but I have my doubts.
Any advice would be greatly appreciated, I could never remove broken bolts for my life, even in the easy places

 

Remove the tct, centerpunch the bolt, and extract it with a left hand drill bit.

Use a coil pack bolt to replace it, they are identical.

 

I had to use a 90 degree corded drill to heli-coil an engine mount bolt-hole on the driver side when mine stripped, you might want to find one of those drills to get that bolt out with an extractor bit.

 

I've never heard of a 90 degree drill before, but it sounds pretty handy in such tight spaces like this
I was able to PB blast it to hell and hammer the protruding edge til the bolt broke free , and then just got a pair of tweezers to twist it out.
For any readers contemplating repairing your TCT, always use new bolts when reinstalling. Breaking a bolt in there is an absolute PIA
Thanks for the advice guys

 

I've never heard of a 90 degree drill before, but it sounds pretty handy in such tight spaces like this
I was able to PB blast it to hell and hammer the protruding edge til the bolt broke free , and then just got a pair of tweezers to twist it out.
For any readers contemplating repairing your TCT, always use new bolts when reinstalling. Breaking a bolt in there is an absolute PIA
Thanks for the advice guys

 

I'm curious in what type of torque wrench you were using. 9 ft-lb isn't much and shouldn't have broken the screw.

 

I hope it wasn't a 1/2" drive torque wrench.

You cannot use a torque wrench on its lowest setting. This has been know in the mechanics world for decades.

In other words, if you have a 1/2 drive torque wrench that goes from 10 to 150, and you set it at 10, it will not click and you will break the bolt.