Thanks to all that replied. I tried the method that was suggested by a listmember where I was able to cut a slot in the broken stud after heating it up with a hard drill bit and high rev dremel drill. I then used a strong screwdriver and more PB Blaster to loosen it up and remove it. I then chased the threads and cleaned up the metal shavings, repacked the bearing and installed the new stretch bolts. Not as bad a job as it could have been if the bolts had been a harder steel. The procrastinating, cussing and thinking about it took more time than the actual repair! Word to the wise-don't ignore that sound that is just like the slightly worn rear hub assembly-check out sounds that change even slightly. This job would have been almost impossible without a lift, drill or the proper tools on the side of the road. Thanks to all that replied.

David Clarkson
90 Westy (245k-on the road again!)

-----Original Message-----
From: Jonathan Poole <jfpoolio@GMAIL.COM>
To: vanagon@GERRY.VANAGON.COM
Sent: Mon, 8 Oct 2007 8:59 am
Subject: Re: removing a broken cv joint stud

Hey David,

if this is on the outer then I would recommend just pulling the stub axle so
that you can get to the problem.  Pulling the stub axle is easy enough and
should only take an extra ten minutes or so removal and reinstallation if
all goes well.  You need to be careful to keep it clean though so that you
don't contaminate the bearings with dirt.

I don't know if it will work but once the flange is out you may be able to
access the nut from the back side.

Jonathan Poole
'82 ac westy

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