I finally got around to changing all of the fluids in my 02 WG. Everything went great until time to take off the derby cover. I stripped the head on one of the bolts. I have already tried using an extractor, but it broke off in the bolt. I have the other four bolts out, but I need help in removing the last one. Any suggestions would be appreciated.

 

If you have access to a small hand grinder (dremel tool), you could use a small cut off wheel and grind a slot into the broken bolt large enough for a large flat bladescrew driver bit. The cut off wheel will also grind into any part of the extractor thats stuck.You could then attempt to back it out witha screw driver or even hit it with an impact tool with a screw driver bit attached. You will probably need a new derby cover once resorting to this, because it probably won't be possible not to damage it after resorting to this method. I hate when stuff like this happens.

 

I have had some occasional luck drilling into the bolt a ways until the bit gets stuck and then reversing the drill. Bad news is that sometimes the bit breaks off too. I'm thinking that the bolt is an alloy material as opposed to stainless steel, so you might have some luck. Also, once the hole is drilled, you might be able to get the extractor bit to grab. Good luck.

 

After you try grinding it as mentioned, if it still isn't out, try using a left hand drill bit, they work very well for extracting broken bolts/screws. You will have to use a cobalt bit and go pretty slow to have any chance of cutting that easy-out.

 

left hand drill bit.....hmmm, never thought of that...

 

Hey has anyone tried this thing out for stripped bolts?
http://www.4grabit.com/Default.asp?bhcp=1

 

Haven't tried it but it looks like a good piece of equipment to have.

 

Derby cover screws are 1/4" in size. Take a 1/4" drill bit, make sure it's sharp, and slowly drill off the head of the screw. Once the head falls off, and the derby cover is removed, simply remove the remaining stud. If your careful, you won't even touch the derby cover.I think we all had this problem once. Itrashedthe remaining torx screws and bought stainless steel socket head cap screws. Not only are they easier to remove, they match the remaining screws on the primary cover.

Good Luck

 

YES!!! I have used that "Grab It", and it works f&*%ing AMAZING!!! Believe me,I've seenA LOT of stuck screws too. Works better than any easy out tool I've ever seen/used...

-Olkie

 

Thanks for ideas. Tdegroot, I was able to make a slot with thegrinder and used a flat head screwdriver to get the bolt out. Took about 1 minute.Skullguy, I already trashed therest of the bolts andjust picked up thenew bolts to match the rest of the primary. Thanks again for the help.