torx bolt striped

[stranger12]

Hi All,
not bike related but here it goes .
bolt head on my car diff is stripped and will appreciate all inputs.

below are some pic

it is e16 torx . I did hammer in e12 and e11 but they also slip . it is driving me mad.

vice grip also slips and grinds off the head .

have used heat and plusgas oil but no result. I think it is mainly due to significant torque required to remove the bolt and because it has no head to grip on to undo then oil and heat are useless.

I have one of those go pro blow torches 1400 degree and kept it on the body of the joint for more than 3-4 mins with no result.

does anyone know how I can take the f*cker out with out drilling it ? I think drilling it will even be harder as it is a tough metal bolt.



one option in mind is to use chisel at angle and if that failed then cut the head off and try to use vice grips and turn it from the stud.


I don't know why the f*cker in bmw decided to use torx head rather than normal bolts. the head is smaller than the body .
is there a reason they have used torx as opposed to normal 6 point socket head?



striped head

https://i60.tinypic.com/2prwj7o.jpg


the bolt diameter which is way bigger than the head

https://i62.tinypic.com/wv1uud.jpg


My little garage in case u are interested

https://i62.tinypic.com/29uvouq.jpg

many thanks
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[i.p.phrealy]

grind 2 faces on it and use an open ended spanner?
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[stranger12]

I don't think that would work. I had to use a half a meter bar to remove the other bolts and with this one I could put a 6 or 7 mm spanner which can not even turn it
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[CHR15]

i would slice the heads off with a grinder, remove the driveshaft and plug weld a nut onto the bolt stub.

what i did on my e46 diff anyway.
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[moonzoomer]

I would suggest getting a length of 1/4 " thick flat bar and drilling a hole in it roughly the size of the bolt head then welding the bar to the bolt head, the heat from the welding will also help as will a bit of longer leverage on the 1/4" bar. Drastic I know but it does work.

[Fisty]

Why you no clean the arse end of the thread before you try to remove? Also give everything a good belt with a copper mallet to shock it free.

Do what Chris said.
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[thomp1983]

another vote for cut them off, if you don't have a welder with the joint separated you should have enough thread to put 2 nuts on and lock them together and wind the remains out

chris

[stranger12]

it seems like i can not get it out any ways or I am not experienced enough with these kind of sh*t

basically did cut the head but the stud is not big enough to allow me to use a vice grip on it .

when I apply heat , I apply it to the body and not the stud, is that the correct way?
I am doing above because I think heat will expand and I want the body to expand not stud otherwise it will make the situation even worse.

i have one of those blow torch , how long should I keep it on the body to ensure it is hot enough ?

now my next option is to cut a thread in the stud and use screw driver but think that will be unsuccessful so if i fail that , I will be drilling it out.

for drilling , I need center drill and iron drill which is one size smaller than the bolt ?

before any of the above I will first try to put two nuts on and tryto get it out as suggested earlier. but I don't think it is big enough to fit two nuts on it
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[c_dug]

A standard HSS drill bit should drill through whatever the bolt is made of.

Not sure what you mean by an iron drill.
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[stranger12]

sorry i am not very good with drill etc. I meant a drill which is made to be used on metal /iron .
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[Aff]

[stranger12]

can I cool it by applying water on it or have to wait ?

when you guys do it , how long do you keep the heat on and how long should I wait for it to cool off.

sorry for the noob question. it is a learning curv for me . not very familiar with these sort of things
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[Aff]

[T0MMY]

I had some joy with a set of these...

https://www.powertoolsdirect.com/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/i/r/irwin-bolt-grip-fastener-remover-base-set-of-5.jpg

Irwin bolt grips. I managed to shift a rounded off, rusty and extremely seized downpipe bolt with one but it killed the bolt grip doing the other two!
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[Llama-Farmer]

Yup use some of them in the post above...

https://www.ebay.co.uk/itm/Irwin-Bolt-Grip-Fastener-Remover-Expansion-Set-Screw-Extractors-Bolt-Grips-/171208988544?pt=UK_Hand_Tools_Equipment&hash=item27dcd9d780



Heat with a blow torch first, for several minutes each bolt. Then allow to cool for 5 or so minutes before a firm* tap on the ends from a hammer cracking off with the extractors.


That should expand them enough to break any seal, allow them to shrink so you can get them out, and the tap for good measure to free them up.


* Firm tap, but not hulk-like. Imagine you're hitting the back of your hand with the hammer. You want it to be hard enough that it'll hurt a lot, but not so hard it breaks your hand/fingers.
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[Llama-Farmer]

And then for future if you ever need to remove bolts that are anciently rusted... apply some penetrant spray at least 24 hours before, maybe even a couple of sprays over a couple of days.

A firm whack before undoing can shock the threads loose.

And if you sense it is gonna slip, stop, and destroy it with fire from the blowtorch... used properly there aren't many things that they won't sort out.
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[stranger12]

have those. it didn't work. I think those are meant for 12 point and 6 point rather than torx heads


did buy my self a set of titanium hss drill from screw fix for £15. it used to be £25 so I am chuffed.

I shall have a go at drilling it later today or tomorrow
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[-]

Have you priced up how much would a used diff be from this lot?

https://www.bmw-spares.com/

Their website says that E34 diffs start from £50, E39 diffs from £75.
By the time you've messed around getting the old one separated and repaired whatever needs doing, it might be just as cheap to get a used replacement. They're up the road from me and are where I get a lot of my parts from.
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[Rogerborg]

[Clutchy]

Another vote for the irwins, around £15 IIRC but worth every penny, I used them on my sump bolt which was badly stripped.


Make sure you get the right size kit as they do 2 I think.
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[stranger12]

Hi all,

Spend almost 1 hour with a titanium drill hss bits to drill the bolt

I could only drill in about 1cm from where the head was cut off

After that it is rock solid nothing goes through it

I not sure if it is because i don't do the drilling right so here is how i did it

Started with a small one and it soon broke so did go one size u and again broke ,.

Hot to 5mm which worked but only 1cm in . I can't get past that.
I have tries lower speed, high speed , pressing the drill as it is drilling and no result

Am i using the wrong drill or drill bit?

My drill is bosch
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[Commuter_Tim]

[Llama-Farmer]

[gavbriggs]

Get a landrover
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[stranger12]

It is a bosch 650w corded . I used my mobile 2 stroke generator to power it,

I think it drilling power is less than 20nm .

Is it the drill that matters or the head?

My drill bits bought from screw fix which are meant to he titanium .

It is goldish color
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