I was just bleeding the brakes on a 1994 civic si w/abs. When I went to turn the bleeder screw on the front drivers side caliper the screw just snapped off (in the 'off' position, I guess I don't know my own strength)

How should I go about extracting the broken screw without any caliper damage? (The screw broke off flush with the rest of the caliper)

Any recommended removable techniques or tools?

I am afraid my usual technique of drilling the crap out of a stripped screw then cold chiseling it won't work here.

 

Try a screw extractor (EZ-Out or something like that) carefully. You don't want to damage the seat down in the bottom of the hole that the screw is in.

But the only time this happened to me, I couldn't get it out that way. I had to find somebody to weld a peice of steel rod onto the broken screw.

 

I have had some bad experiences with some of those ez-out, but I think I'll give it a try.
I would just weld something to it, but the screw is flush with the caliper and is only about .4 of a cm thick.

 

Yeah well, I didn't say it was EASY to weld something on it...

I'd try taking some rod, grinding it to a point like a pencil, and bending it to the shape of an L, kinda like an allen wrench. Then you just gotta be good with welding small stuff.

Or, take out the other bleeder screw so you know the exact size. With some searching, you might be able to find a left-handed drill bit. Just about the size of the shank of the bleed screw that sits down inside the hole, beyond the threads. If you're careful centering it, you can drill without screwing up the female threads in the caliper. When you get in far enough, the bit will maybe catch & pull the part out.