If all else fails, slip some copper tubing(or rolled pop can) down the hole till it hits bolt, fire up the stick welder, and tack a rod on it. The copper tubing keeps spatter off the threads, and you get a solid connection to twist with via the rod.

Never did it on a crank though, so don't hold me liable if it makes your cat learn line dancing, eats your shredder, or saves the planet.

<img src="/forums/images/graemlins/lol.gif" alt="" /> classic

Never thought of using an impact, but makes a lot of sense, like most stuff you say on here Eddy. Thanks everyone, I was a lost puppy and you guys showed me the way. Thanks again.

Finally got around to getting a look at this and the key way is sheared off, now what? I am really not happy with Mitsi right now and would be crazy to ever own another.

Don't be too pissed off at Mitsubishi, they've done what they could to rectify the problem. There was a recall on the crankshaft bolt that included an updated part and torque value. In addition to that, the issue comes up monthly on this forum in one way or another. There's really no reason for any Montero owner that reads this forum to still have the original crankshaft bolt in their engine.

yes, yes. Good point, from what I found '91 wasn't recall year (but should have been). If I would have just been aware of the situation and fixed it before it did what it did i guess we wouldn't be having this conversation. So equal parts pissed at Mitsubishi for such an obvious flawed design and myself for not being proactive in car maintenance.

OK. Everybody has said some people have fixed this. I DID. My pulley was toast and my bolt broke and the keyway was sheared on mine. Is there still somewhat of a slot in the shaft? if so the slot is to line up everything- The bolt actually holds it in place. My was really hard because when I did my t-belt I had used Locktight <img src="/forums/images/graemlins/zombie.gif" alt="" /> Now to removing it: I did use L handed bits and a small drill. I beat the crap out of my forearms trying to be careful. I ended up drilling the center out and basically had a thread tube <img src="/forums/images/graemlins/smile.gif" alt="" /> Then I made a pick out of an old allen wrench. I used this to work into and bend the edge of what was left in the hole. Once i had the edge bent, I took needle nose vice grips and unscrewed the "thread tube" out! Then I took a thread cleaner (kind of like a tap) And made sure threads were clean. The one thing I did not do was change the crank seal while I was there and now soon and am going to havta do this. I have around 10,000 miles on truck since this was a done. Hope this helps! BTW My truck has 267,000 miles on it. Bolt lasted pretty good LOL!

The black truck I picked up had the bolt back off and trash the balancer and a little bit on the snout. Did clean up nice and runs. I'm the one idiot that hasn't changed the bolt my other monty yet. I will this weekend though. I've seen people tack a bolt on top off broken bolts and pull out the busted one that way, but not me. I can't weld to save my life. (BTW my white one has 287,000.)