1. Extraction Tools:
* Easy-Out/Screw Extractor: This is your first attempt. Drill a pilot hole (slightly smaller than the bolt's diameter) into the broken bolt, then carefully use an easy-out or screw extractor to grip and remove the remaining piece. Go slowly and apply even pressure to avoid further damage. These can sometimes fail if the bolt is severely damaged or hardened. Different sizes and types of extractors exist, so choose one appropriate for the bolt's size.
* Bolt Extractor Set: Similar to an easy-out but often with more robust designs and various tips for different bolt sizes and shapes.
2. Drilling and Replacement:
If extraction tools fail, you'll likely need to drill out the remaining bolt.
* Precision Drilling: This requires patience and careful drilling. Use progressively larger drill bits, starting with a small size, and ensure the drill bit is centered to avoid damaging the surrounding threads or engine block. You'll want to drill the bolt out as much as possible without damaging the block.
* Bolt Repair Kit: Some kits provide helicoils or time-serts. These are threaded inserts that replace the damaged threads, allowing you to install a new bolt. This is a more permanent and reliable solution than simply drilling it out and hoping for the best.
3. More Aggressive Methods (Use as a last resort):
* Welding a Nut: If you're comfortable welding, you might be able to weld a nut onto the broken bolt. Let it cool, then use a wrench to remove it. This requires skill and caution to avoid damaging the surrounding area.
* Drilling and Tapping a New Hole (Advanced): In a worst-case scenario, you might need to carefully drill out the completely broken bolt, tap a new hole next to the old one, using a slightly larger diameter, and then use a longer bolt. This is only recommended if you have experience with machining and threading. Incorrectly done, this will weaken the engine block.
Important Considerations:
* Access: Getting to the starter bolts on a Silverado can be challenging. You may need to remove the starter motor itself for better access. This usually involves disconnecting the battery, disconnecting the starter wiring, and potentially removing other components like the exhaust manifold heat shield. Consult a repair manual for specific instructions for your vehicle.
* Penetrating Oil: Before attempting any method, liberally apply a penetrating oil (like PB Blaster or Liquid Wrench) to the broken bolt. Allow it to soak for several hours, or even overnight. This can help loosen the bolt.
* Safety: Wear safety glasses and gloves throughout the process. Use caution when drilling to avoid injuring yourself or damaging the engine block.
* Repair Manual: A repair manual specific to your 1995 Chevy Silverado is invaluable. It will show you the exact location of the starter bolts, the proper procedure for removing the starter, and torque specifications for the replacement bolts.
If you're not comfortable performing these repairs yourself, take it to a qualified mechanic. The cost of professional repair will likely be less than the cost of potentially damaging your engine.
