Snapped a wheel bolt
 

I somehow got it into my head that the torque spec was 50 ft-lb when it's 26. I've been tightening to 50 since day one, and should have realized that I was overtightening because it always felt like the head was slipping in the plate. Now I realize that the bolts were twisting.

Does anyone know if it's possible to replace the plate assy without having to send the whole gearbox back? I assume I should replace both while I'm at it?

a bit confused....are the stripped? If they are e hilicoial...(sure I spelled that wrong)....More info and there are some options

An easy out takes drilling and has to be done from behind

Just found this:

http://forums.segwaychat.org/showthread.php?t=24087

It appears you will need to replace the mounting plate assembly.

I just got word from the factory through my dealer. The plate can't be replaced; I need a whole new gearbox, for $537 incl shipping.

This unit has almost 12K miles, but still runs like new, so I'll cross my fingers that I can get another year or two out of it.

There is more than one way to skin a cat.... Talk or take it to a machine shop, they will have much cheaper options!

I was thinking maybe the broken bolt could be drilled out, and a nut welded to the back of the plate, over the old head, but there's not enough space.

What if I drilled and tapped a couple 12-24 holes in the plate, one on either side of the broken bolt, then drilled holes in the wheel for bolts? The plastic would have to be cut away around the new holes so the heads could rest against the metal insert in the wheel. I'd also use lockwashers and thread-locker.

Do you mechanical types think that would work?

Perhaps you can get a wrecked segway for short money, and use the transmission from that.

I think that's a good suggestion from Karl, worth checking into at least. About 6 weeks ago I had a battery melt-down that ended up in me getting a new seg,
and I salvaged what I wanted off the old one and let the dealer have the "wreckage." So my dealer would have had the necessary parts to scrap from at some point, maybe others would as well. Other more handy folks may end up keeping the whole thing and you could try an on-line hunt as well.

good luck

My 2008 I2 has over 8k miles and I've never thought of tightening the wheel bolts. (I suppose they were tightened by the dealer when I bought 3 sets of new tires.)

Were you having wobble or noise issues?

I think that would work if your objective is to mess up a wheel. But if you actually want to get the problem fixed, then consider airdale's suggestion to take the problem to a local machine shop. And/or look on eBay for what you need, or ..........