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Thread: HELP!!!! stripped bolt head!!

  1. 22nd December 2019, 01:21 PM #1
    southaussiematt Guest

    HELP!!!! stripped bolt head!!

    Hey guys.

    Well I have been slowly stripping down Bessie (2000 D2 TD5), to replace oil cooler gasket, and all associated gaskets and o-rings

    Everything has been going smoothly UNTIL......

    The bolt on the left of the centrifugal filter has corroded and the head is stripped, so I am unable to remove the bolt.

    Filter bolt.jpg

    Can anyone suggest a way of getting the bolt removed? It is in a bastard of a position. This has now become a show stopper for me as I cant remove the oil cooler housing without removing this bolt (I think).

    Cheers

    Matt
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  2. 22nd December 2019, 02:21 PM #2
    Graeme
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    Can you drive an undersized socket onto the head?
    MY21.5 L405 D350 Vogue SE with 19s. Produce LLAMS for LR/RR, Jeep GC/Dodge Ram
    VK2HFG and APRS W1 digi, RTK base station using LoRa
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  3. 22nd December 2019, 02:31 PM #3
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    stevo
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    make sure it is a single hex socket it will get a better grip
    disco seriesII mods so far:-bullbar,hyd winch,
    detriot locker,lsd front,C.D.L kit,chipped and bigger intercooler,2" lift,rock sliders, lsd in transfer case, modified auto trans.

    In the event of nuclear war,Disregard this message
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  4. 22nd December 2019, 02:38 PM #4
    gofer
    gofer is offline Master Supporter
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    hex socket x 2 :-)) i.e. 6point.
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  5. 22nd December 2019, 03:07 PM #5
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    p38arover
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    None of the above. Try a Metrinch or similar flank drive socket. They put pressure on the flats, not on the corners of the hexagon.

    I've used them to remove exceptionally rounded nuts.

    Ron B.
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    Previous: 1983, 1986 RRC; 1995, 1996 P38A; 1995 Disco1; 1984 V8 County 110; Series IIA



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  6. 22nd December 2019, 03:16 PM #6
    BradC
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    I bought my Metrinch set 20 years ago and it had been the best purchase bar none. When it really turns to mush I TIG a nut to the top of the bolt head if I can get in there.

    If that fails it's down to the mag drill and left handed drill bits, and if they fail then my neighbour has an EDM. The Metrinch set usually get it though.

    If you drill it and use an EZ out which invariably snaps off, then it's concentrated nitric acid or the EDM to remove the remains of the EZ out.

    There are guys all over the country that specialise in removing toasted fasteners. If it's really bad, sometimes it's worth seeking expert assistance rather than making it worse.
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  7. 22nd December 2019, 03:21 PM #7
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    rick130
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    Kinchrome and several other tool makers make sockets that lock on, designed specifically for rounded heads.
    They work well.

    Kincrome - LOK-ON Overview
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  8. 22nd December 2019, 04:41 PM #8
    Graeme
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    The effectiveness of any of the socket options is often enhanced by using an impact driver, in this case using a socket extension. The sharp jolts from the hammer assists in loosening the bolt or screw - just be sure the tool is set to the correct turn direction..
    MY21.5 L405 D350 Vogue SE with 19s. Produce LLAMS for LR/RR, Jeep GC/Dodge Ram
    VK2HFG and APRS W1 digi, RTK base station using LoRa
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  9. 22nd December 2019, 07:13 PM #9
    southaussiematt Guest

    Thank You

    Thank you everyone for your assistance.

    I used the 1 socket size down trick and was able to undo the bolt.

    Once again

    Thank you

    Matt
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  10. 23rd December 2019, 11:59 AM #10
    AK83
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    Quote Originally Posted by rick130 View Post
    Kinchrome and several other tool makers make sockets that lock on, designed specifically for rounded heads.
    They work well.

    Kincrome - LOK-ON Overview
    Quote Originally Posted by southaussiematt View Post
    Thank you everyone for your assistance.

    I used the 1 socket size down trick and was able to undo the bolt.

    Once again

    Thank you

    Matt
    +1 to Ricks comment.
    I had a similar bolt head issue on my Tdi trying to remove fan pulley. The head was already semi knackered, so tried to remove very carefully, but failed.
    I thought I had one of those multi pinned multi sized sockets that form around the head, but didn't.
    Tried a few methods till I gave up and went to shops to see what's available, and I have a Bursons within walking distance from me.
    Chap 'highly recommended the Kingchrome Lok-On sockets, and I have far too many sockets already, but relented when he said mentioned money back guarantee if they didn't work.

    Worked absolutely perfectly to the point that I didn't take them back, even tho that was going to be my evil genius plan. . ie. to remove it, and go back claiming that it didn't work.
    But they work so well they are my primary go to tools now for anything that will allow their use. I just got the 3/8 drive set, and so have 'abused them' quite a bit in using them for work that really should have seen a 1/2 drive set used.
    The 3/8th kit wasn't cheap, but still worth it, even tho I did break the ratchet wrench on one job.
    Arthur.

    All these discos are giving me a heart attack!

    '99 D1 300Tdi Auto ( now sold :( )
    '03 D2 Td5 Auto
    '03 D2a Td5 Auto
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