Bolt Extractor to Remove Stripped Transmission Support Bolt on BMW E39

I broke a support brace bolt, while replacing my old transmission mounts on the E39. The bolt was broken at the head, and the threaded shank was left in the hole. I heard it snap and felt sick to my stomach. It was the last bolt to be removed to the brace and I didn't know what to do.

I looked online and apparently, breaking transmission support brace bolts is common. They are exposed to road salt, and get rusted out. Drive train components last for years before maintenance, so these bolts don't get taken out often.

The solution:

• Extract the broken bolt with a screw extractor. 
• If extraction doesn't work, drill it out. 
• Rethread with tap and die, if female threads are stripped
• Helicoil, if cutting threads doesn't work with tap and die

Broken bolt and stuck screw

I purchased the Werkzeug damaged and stripped screw extractor set and a  a Gearwrench Ratcheting Tap and Die set as well. There are 22 pieces and it comes with an magnetic extension bit holder and socket adapter.

I placed the bit holder in my drill, and picked the smallest driller. I started drilling, and had some difficulty establishing a clean hole to use the bit. I lowered the drill speed and alternated between driller sizes. I was really skeptical at first, because the bits are so small. I questioned myself, if I was doing this right at all, and if this would even work. I pressed on, out of desperation.

After 25 minutes of drilling, I finally got a good clean hole and put in the extractor. I pressed the trigger and could see the screw turning a little but it stopped. So more drilling, with a larger driller. I stepped up the extractor to #6 and the broken screw finally came out. I was elated and so happy.

Broken screw with extractor tool

Broken screw removed

I cleaned up the threads with a tap and die, removed and replaced the old transmission mounts, and put in a new support bolt into the brace.

The $20 extractor kit saved me a trip to the shop. Every do-it-yourself mechanic needs to have one of these. It is such a lifesaver, especially in tight spots where cutting the bolt is not feasible.

BMW Transmission Malfunction Warning

BMW Transmission woes.

I was driving a E90 335i and merging onto the highway when a yellow gear with an exclamation showed up on my dash. iDrive said "Transmission Malfunction. Drive moderately and Reduced Acceleration."

The transmission was stuck in gear and would not downshift or upshift. This was particularly scary going from 75 mph to 45 mph and driving way too slow on the highway. I got off at the nearest exit and quickly pulled over. I shut the car down and then restarted and the warning went away.

Everything seems normal and I have made a service appointment at the dealer to see what is going on. The 335i is under CPO warranty. I will keep you posted on what BMW says.

Symptoms: I noticed the 335i was awkwardly shifting and slipping before I got on the highway. A month ago I was stopped at an intersection and when the light turned green, I took my foot off the brake and the car lurched forward. When I am coming to a stop on a downhill road, the car will shudder and I hear a grinding noise.

Result: Transmission fluid was two quarts low and the fault only occurred once.