Bad situation that I have made worse.

Took the ABS modulator block off to do the SVS mod, rather than in situ as last time i took the switch off with the lines attached but managed to cross thread a bolt. Did the soldering and went to bolt switch back on. This time the bolt broke off. Drilled though it very easily and inserted a stud remover. This snapped off so I am having to drill this out.
It is hard. Any special tips for drilling through hardened steel?
Will helicoil fix the messed up hole?

Not much experience but I'd think a proper quality bit or 3, nice and steady not too fast and plenty of 3in1 oil to lubricate. Would imagine it would take a while. Secured on a bench with a pillar drill as well.
Can't see why a helicoil wouldn't sort it but again never actually used one.

**** when stuff like this happens I feel for ya

After trying dormer drills and cobalt drills, I tried a masonry bit and that did the job. I have ordered a helicoil kit which should come tomorrow. I have never used one either but there are so many things I hadn't done till my wife got this land rover eleven years ago. I feel more hopeful now. Its great having this forum to share ones woes.

The kit will come with the correct size drill bit, if the 'mess' you've made getting the extractor out has left a hole bigger than the bit it won't work.
I don't know the thing to which you refer having never owned a vehicle newer than 1986, but there will be a work around I'm sure if the 'mess' is too big. Next size up and drill out the thingy to suit or a reducer stud are a couple of options.
Kit is easy to use, just follow the directions.

Maybe post some pics, I bet @jamesmartin is handy with helicoils

I don't think I have opened it up too much. I will know for sure when the kit comes tomorrow. I have loosely put the shuttle valve switch back using the two good holes and put the modulator block away in the garage. I should have used an Allen key rather than an Allen bit with a socket driver.

1988smithy said:

Maybe post some pics, I bet @jamesmartin is handy with helicoils

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i use the recoil kits they are a little easier cheaper and come with all you need, i do alot of stud removal and thread repairs

Flossie said:

The kit will come with the correct size drill bit, if the 'mess' you've made getting the extractor out has left a hole bigger than the bit it won't work.
I don't know the thing to which you refer having never owned a vehicle newer than 1986, but there will be a work around I'm sure if the 'mess' is too big. Next size up and drill out the thingy to suit or a reducer stud are a couple of options.
Kit is easy to use, just follow the directions.

Click to expand...

A complete Helicoil kit will contain the correct size drill bit to clean up the hole, a tap to run in the correct size thread, a device to"pull" the Helicoil into the hole; the little "tang" must be at the bottom so that the screwing effort is from the bottom and another device to fit into the finished thread to break off the little tang at the bottom.
Now that you've opened up the brake line at the ABS modulator you're probably going to need a code reader to "power bleed" the brake system. I'm sure that others will be able to advise you on that job.

I have used my Lynx to powerbleed the brakes before so I am hoping that won't be too much of a problem. I have ordered this cheap 'helicoil type' kit which should come tomorrow. I just hope I don't regret getting the cheapest. Any idea what the torque value should be for the allen screws?

brianconwy said:

Any idea what the torque value should be for the allen screws?

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It's not very much at all, if I remember right it's about 9 lb.ft.
Just do them up tight with an allen key, it's so little force as not to matter that much.

The kit arrived and all sorted. I was surprised how little time it took. The silverline kit seemed pretty good for the job. Thanks for the help.

brianconwy said:

The kit arrived and all sorted. I was surprised how little time it took. The silverline kit seemed pretty good for the job. Thanks for the help.

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If you're doing any work on an aluminium engine or diecast sh1tite parts, a Helicoil kit or similar is almost essential. I got one like this some time back:-
https://www.ebay.co.uk/itm/UK-131-P...=item25c440b885:g:I98AAOSw2s1Uydrw:rk:17:pf:0
Additional coils of various lengths are easily available too.

Added to my wish list.

You could have glued the bolt back in with some super glue.

Col