Originally Posted by Grumps
I did the same thing, last bolt and last little snug. Filled the hole with permatex and will replace all screws when covers start leaking again.
These screws are really simple to remove with an 'easy out'. I simply center punched the broken thread & drilled the pilot hole using a 5/64" drill bit. And you don't have to drill a very deep pilot hole. Then using a #1 'easy out', the broken screw came right out. (Note: The broken screw is aluminum so the screw extractor or 'easy out' will grab real easy.) Didn't even have to remove the breather cover to perform this repair. And as I stated earlier, I replaced all the aluminum M5-.80x16 Torx SHCS with standard carbon steel Hex SHCS's I found at Lowe's.