basically I was doing a repair to the gearbox and when putting the the main support back on to the gearbox (front support) one of the bolts has snapped the thread on the chassis and it looks like in going to have to cut the bolt to get it out.

What is the easiest way to repair this?

 

what bolt are we talking about here mate as i has similar problem

 

At a guess I would say one of the two 19mm bolts that hold the front of the cradle on.
The problem is that the cradle can sometimes distort just enough to make it very tricky lining the bolt up and ultimately can lead to the sheering or worse spinning of the nut inside the chassis if not extra carful.

With out seeing this it’s hard to give a definite

If the bolt has rounded and the nut chassis side is still intact and not spinning you should be able to cut and drill this out, rethread the bolt in situe with out to much bother.

You may also consider a smaller drill bit to drill the centre of the snapped bolt leaving only a few thou allowing you to collapse the remaining bolt leaving the thread on the nut intact.

This is of course we are talking about the same thing here.

 

it is the long cradle at the front,17mm bolts, it has spun the nut inside the chassis

 

How much thread is left on the bolt?

If could cut the bolt head of exposing the remainder of the thread, drill through the chassis and pin the nut that has spun i.e. have some way to hold this in position and stop it from spinning.

Then with the remaining of the bolt you have just sheered you may have enough thread to attach a nut to the underside allowing you to tighten the cradle.

 

same problem i had mate, personally i wouldn't be grinding any head off the bolt to try attatch a nut.

what i done was drilled a hole in my floor where the nut was located, got a spanner onto it and undone the bolt from the nut. if you cant get it undone grind the bolt in half and pull the nut with remains of bolt out from inside the car, then use a new nut and bolt, but you'll need to use a spanner to hold the nut in place

when i done this to my car the nut was fine so all i done was replaced the bolt.

 

managed to repair it today, I cut a flap around the hole, welded a nut to the back of it,welded back in place.........sorted.

 

 

A what point did I mention grinding, you make it sound like a bodge when in fact this would have been the cleanest option assuming of Corse there was enough of the bolt to work with as mentioned in my first post.

Anyway I’m Please it’s all fixed now.

 

im pleased that it is fixed but guess what.....there is still a noise on overrun and I aint got a clue where to try next.
I changed the bearings in the transfer case as the drop gear bearing was a little worn and causing a bit noise on overrun.Noise isnt as bad but can still be heard. Checked the diff and prop and still there.