Carrier bolt sheared and stuck in hub

[Benjy911]

So today I set about changing the front discs and pads on my S3 and so far after 6 hours I have one side apart and am stuck!

As I was changing the disc I set about removing the calliper carrier, the top bolt came undone fine however after probably too much brute force the bottom bolt sheared off. It was then that I realised I could just swing the carrier down with some more force and remove the disk

After this slight drawback I set about drilling the bolt out...4 drill bits down, 5mm into the bolt and I realised it wasn't going to be that simple so I went off and had a think. On return I swung the carrier down a bit more and realised that the bolt was actually seized within the hub where it attaches to the car, which is totally smooth and not threaded like the carrier. With this new found knowledge I've tried prising the carrier off with a breaker bar between it and the hub, lots of smacking with a hammer and also heat, none of which have got the bd off!

Has anyone had this issue and if so how did you solve it?

[Benjy911]

Your understanding is indeed correct, thank you for your suggestion.

I'll try it tomorrow and report back, the gap is quite tight as it'll only swing down to about the 6 o'clock position but some force might squeeze one in!

[Benjy911]

So far no luck! I've been trying most of the morning and it just won't budge. Unfortunately there isn't space for a washer so I've tried a puller but that just ended up slowly pulling through the hub, I've also tried more heat but it seems totally stuck in there.

I'm starting to wonder if someone has put locktite or similar on the bolt, but you'd have thought that would have melted off with the heat? Wish I hadn't started doing them now!

[Benjy911]

Thanks for the suggestions, but I've given up and taken it to a garage!

For heat I was used a butane and propane mix, probably not hot enough though as I never got it glowing?

In terms of sliding the carrier off, the bolt was threaded onto the carrier and would only swing down 90 degrees so wasn't going anywhere. The hole in the hub was unthreaded so in theory it should have just slid out once the head had sheared off, however it appears something has got it stuck. Corrosion, sealant, I'm not sure, but the garage can struggle on!

[Benjy911]

To update, the garage got them all out and put my new discs and pads on all round as I'd got quite fed up doing it and just wanted to drive it again! All the bolts needed lots of heat to remove and far more than I could have done so it was probably lucky I didn't snap any more off! They reckoned that the car had probably been stood in a field or similar when new for a while as they were all very corroded into the hubs.