Ideas removing broken DEM / Haldex bots off - 2005 XC70

[kef]

Greetings All,

I have a 2005 Volvo XC70 at ~260 k miles. Recently, I lost AWD function; I noticed that the rear wheels were not spinning driving in snow. I followed XEMODEX's diagnostic flow chart which pointed the problem to the DEM.

I tried to slowly remove the two 4 mm allen bolts - moving them back and forth, but they eventually broke off anyway. I read https://www.volvoxc.com/forums/showt...highlight=1A64 and VTL had showed a method of removing the top bolt off by cutting a channel (I get that). My problem is that I don't have a lot of room to make a cut on the housing as the whole unit is still attached to the car.

If you look at the picture, the bottom broken bolt has plenty of stud to grab on to, the top one just a little.

I would appreciate ideas to remove the studs. [Minus welding a nut]

Thanks!
-Kef