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I wasted about three hours with a stripped bolt. I finally borrowed a Dremel and cut a notch across the face of the bolt. I took a flat head screw driver and hit it with a hammer so it would rotate the bolt counter-clockwise. It came loose on right away. Thank you Dremel!
I'll never forget I was going to restore a 56 Mercury, and was dismantling it. There were some mirrors on the fender that were held on to the bracket with a set screw. I went out every day and hit em with penetrating oil, and they wouldn't come loose. Then one day I remembered that sometimes if ya tighten the bolt first, it will break loose. I tried to tighten the bolt, and it came out like butter...They were left hand threads...lol
I removed the factory torx bolts and replaced them with chrome allen bolts and washers because the first bolt I went to remove the head almost stripped out. I think the torx bolts are cheaper and faster to install at the factory. The chrome allen bolts look much better and come out easily.
I use a long-handled screwdriver type torx bit, you're much less likely to overtighten the bolts. As said, they just need to be snugged up, that's all, no tighter than that.
FatBoyVeteran, great advice.
I replaced the torx zinc looking stock bolts with polished stainless allen head bolts and washers I got from Ace Hardware.
..that's on my to-do list for this winter as well.
I already bought the bolts for the derby & cam covers - those torx bolts suck...
They make an impact driver that you hit with a hammer to "shock" the screw, It puts an extreme amount of torque on the fastener almost immediately. Also you might try a Dewalt impact driver, or other make, to get it out. I once had an aluminum screw in a steel threaded hole that I had a b*tch of a time getting out. Put a staight screwdriver bit in my battery operated impact tool and it back oput just that easily. A little Nox-Ox when I reinstalled and all is well.
It always seems to be more difficult to remove those screws than installing them. When I have trouble I use a hand impact driver with the torx bit. It works for me.
My father n law had a tough time getting his off. He was actually replacing the cover and had to drill around the bolt through the cover and once he broke the cover off he removed the bolts with vise grips. His was factory and never been touched. I'm not sure if they didn't tap the holes right or used the wrong lock tight. But this sounds like a factory problem.
You've received a ton of advice on undoing what's been done.
Looking forward so this doesn't happen again, someone suggested a torx screw driver since it will fit more snuggly than the typical shade tree mechanic's ratchet bit. I agree. But - I suggest doing a Google and buy the two most used torx bits but make sure they are made by Snap-on. This situation shouldn't happen again unless a torque wrench isn't used.
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