Rounded manifold bolts -help
Thread Starter
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Cruiser
Joined: Dec 2017
Posts: 137
Likes: 24
From: NY
Rounded manifold bolts -help
07 FXDB
The 2 tough ones are now rounded. These are the 2 bolts at the primary side of the manifold. This is not my first time taking the throttle body/manifold off.
So the two on the throttle body side I got loose no problem. But the two on the primary side are impossible this time around.
I used my special 1/4” angled ball Allen wrench, but it’s just mangling that soft bolt.
So, considering the tight space I’m working in, what are my options?
How can I get these out?
Thanks.
The 2 tough ones are now rounded. These are the 2 bolts at the primary side of the manifold. This is not my first time taking the throttle body/manifold off.
So the two on the throttle body side I got loose no problem. But the two on the primary side are impossible this time around.
I used my special 1/4” angled ball Allen wrench, but it’s just mangling that soft bolt.
So, considering the tight space I’m working in, what are my options?
How can I get these out?
Thanks.
Tourer
Joined: May 2016
Posts: 318
Likes: 124
From: Alberta
Take a 1/4" allen wrench and , using a zip wheel in a die grinder , cut a piece of the allen wrench off. Take the "bit" you just created and put it in the bolt you want out , get it in there as best as you can. Use a long 1/4" box wrench to loosen the bolt . I've taken off several hundred manifolds / throttle bodies , sometimes you are better off to just start out like this and not wreck any bolts.
Thread Starter
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Cruiser
Joined: Dec 2017
Posts: 137
Likes: 24
From: NY
Take a 1/4" allen wrench and , using a zip wheel in a die grinder , cut a piece of the allen wrench off. Take the "bit" you just created and put it in the bolt you want out , get it in there as best as you can. Use a long 1/4" box wrench to loosen the bolt . I've taken off several hundred manifolds / throttle bodies , sometimes you are better off to just start out like this and not wreck any bolts.
The 1/4” Allen socket cap head is already rounded. So, it doesn’t seem that this will work. Although it is a good idea to get these bolts out (before they are rounded).
If there was any room, I wish I can hammer in a torx bit, but there’s no way I can hammer it in based on angle.
Road Warrior
Joined: May 2011
Posts: 1,956
Likes: 437
From: florida
First w heat gun heat up the bolt area. And have ready a mix gritty cement mix or any compound you can add some coarse mix to it. With finger fill in the stripped Allen head let it sit for handful of minutes then work in the Allen bit. Keep pressure on the Allen wrench and try getting it to turn.
Seasoned HDF Member
Joined: Apr 2014
Posts: 5,420
Likes: 2,484
From: Lititz Pa
I have used needle nose vice grips before. But someone said cut a Allen wench and glue it in place Something like JB weld
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Grand HDF Member
Joined: Nov 2009
Posts: 4,315
Likes: 1,663
From: Tampa
There's enough room to get a good set of beefy vice grips on the head, just crank it down as hard as you can and give it a turn. You only need to break it loose, then the allen can finish the job.
Also, those ball head allens are NOT meant for high torque applications, especially at that size. Get yourself a sacrificial 1/4" allen wrench and cut/bend it to work with those back bolts. Or change them out to a hex bolt you can put a box end wrench onto.
Also, those ball head allens are NOT meant for high torque applications, especially at that size. Get yourself a sacrificial 1/4" allen wrench and cut/bend it to work with those back bolts. Or change them out to a hex bolt you can put a box end wrench onto.
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Seasoned HDF Member
Joined: Mar 2010
Posts: 21,007
Likes: 7,541
From: Poolville
I have taken an Allen wrench and taken a little bit off the end of it to make it easier to get into the bolt. If you rounded it with a ball end Allen wrench you'll still have some meat down at the very bottom of the cap screw where you can put an Allen wrench in there. Seat it down with a hammer like I stated a cut off Allen wrench just to break it free It works..