After breaking off the bolt in the oil sump case flange, I tried several techniques to remove the bolt. I tried a screw extractor; however, when the pilot hole was drilled, it wandered a little off center. With such a small bolt, this is a problem. It seems to have partially cut into the casing threads. I did not notice this at first and I tried the screw extractor. It broke off into the bolt. Since I could not reach it, I had to remove the sump once more.
When I go the sump off, I was able to remove the broken tip of the screw extractor. I tried to drill another hole, but it became apparent that the case threads were too messed up.
The fall back was to drill and tap a larger hole and install a helicoil. The bolt is a 1/4-20. This worked out well with one minor problem. The heli coil did not seat all of the way down and left a minor protrusion above the flange surface. I used a Dremel and ground it down. There are a few minor nicks in the flange surface but the gasket sealer should work on these fine.
The oil sump was reinstalled with a new gasket. All bolts were torqued to 96 in-lbs.
