OK, What Does a Dummy do Now?!
Thread Starter
Instructor
Joined: Jan 2011
Posts: 165
Likes: 0
From: Eureka Ca
OK, What Does a Dummy do Now?!
Car is an '86 with a stock motor....working on the EGR switch trying to get the 2 Torx screws out to replace the EGR tube. I was able to get the top one out, which I actually thought would be the more difficult one, and I managed to strip out the lower screw. Has anybody come up with any unique or special method to get one of these bloody screws out?
Le Mans Master
Joined: Oct 2006
Posts: 6,842
Likes: 285
From: Palmdale CA
You have a couple of options and they're not easy. You can try pounding in a larger torx bit and applying a ton of torque from the top to avoid slippage. Second option is to get a screw extractor set from Sears and that's what I did on the one I stripped on the manifold. The set will tell you what drill sizes to use to drill a hole into the fastener. Then you pound the extractor into the hole (straight in the hole, not cocked sideways a little) and apply the T-handle to the extractor and twist out.
Thread Starter
Instructor
Joined: Jan 2011
Posts: 165
Likes: 0
From: Eureka Ca
You have a couple of options and they're not easy. You can try pounding in a larger torx bit and applying a ton of torque from the top to avoid slippage. Second option is to get a screw extractor set from Sears and that's what I did on the one I stripped on the manifold. The set will tell you what drill sizes to use to drill a hole into the fastener. Then you pound the extractor into the hole (straight in the hole, not cocked sideways a little) and apply the T-handle to the extractor and twist out.
dws
Le Mans Master
Joined: Mar 2004
Posts: 5,107
Likes: 171
From: Dublin CA
....TRY the next size LARGER torx bit FIRST before you start drilling and using a easy out.Before you use the larger torx, hit the bolt with PB Blaster or another good penetrating agent...NOT WD40!. Let it sit 24 hours to help loosen the bolt ....then try the larger torx. Tap the larger torx into the existing hole. Then apply as much downward force as you can onto the bolt as you start to turn...remember turn it to the left to loosen.
Safety Car
Joined: Aug 2009
Posts: 3,752
Likes: 276
From: Melbourne, Victoria, Australia
Remember easy out's are so fragile, break that and you are in a whole lot of trouble 
If you break the easy out ,,,,and you can easily obtain another torx bolt
there is an alternative.....
Well its nasty
but a hammer and cold chisel in careful hands on the (torx head) will get that nasty torx out quite easily do it from the top and not the side ... don't want to wreck the manifold .... 
If you break the easy out ,,,,and you can easily obtain another torx bolt
there is an alternative.....
Well its nasty
but a hammer and cold chisel in careful hands on the (torx head) will get that nasty torx out quite easily do it from the top and not the side ... don't want to wreck the manifold ....
Drifting
Joined: Sep 2002
Posts: 1,642
Likes: 0
From: Suwanee,Ga
....TRY the next size LARGER torx bit FIRST before you start drilling and using a easy out.Before you use the larger torx, hit the bolt with PB Blaster or another good penetrating agent...NOT WD40!. Let it sit 24 hours to help loosen the bolt ....then try the larger torx. Tap the larger torx into the existing hole. Then apply as much downward force as you can onto the bolt as you start to turn...remember turn it to the left to loosen.
Soak it well, and tap it with a small machine hammer.
Heating it with a propane torch may help as well. Then soak again.
If you can get the next size larger to bite, a bit of tightening can sometimes do the trick.
Good luck. Lousy place to try and Easy Out?
TJM
Racer
Joined: Dec 2010
Posts: 302
Likes: 0
From: delancey new york
Your not a dummy! This is a age old problem. Leave drilling and easy outs for last resort. PB blaster- i heat and spray several times and let it sit overnite. Some machinist use candle wax. They heat the screw or bolt then touch candle wax on it and it draws in and lubricates.
Advanced
Joined: Jun 2009
Posts: 50
Likes: 0
From: Surprise AZ
and vote for the heat & "soak in PB blaster for a day and then tap-in the next bigger bit, and applying lots of downward force while turning as a next plan of action", having a “helper” is good, (if you have an extra bit to sacrifice, doesn't matter what type as long as it's big enough and you can put a socket on it, you can grind it into shape where you have to tap it in, makes for a better fit if the next size torx is too big and anything else is too loose.). Tapping on the side with a cold chisel to rotate it is worth trying too, just be careful not to snap it off as there's one more step I like to try before going to the drill and easy-out method. Best luck I've had when all else fails is: tig welding on something, like a nut in this case and turn that, if you have access. Disconnect your battery cables first before welding, clamp-on the welding ground clamp next to area that is being welded. After it's cooled from cherry red, read not glowing, apply some wax, in most cases you can turn out the fastener by gloved hand. Good luck
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Team Owner
Joined: Mar 2001
Posts: 54,124
Likes: 30
From: Cincinnati, Oh USA
If the bigger Torx bit doesn't work, use your Dremel tool and a thin grinding wheel and make a slot on the screw head and then use a straight blade screwdriver to unscrew after soaking with penetrating oil which by my experience is Kroil. I also use alcohol when I don't have Kroil around. Use your screwdriver by tightening, loosening with more torque each cycle on the loosening. Good luck.
Le Mans Master
Joined: Mar 2004
Posts: 5,107
Likes: 171
From: Dublin CA
I am going to assume that somehow with all the suggestions that you got the bolt out. Before you screw in the replacement.....put anti-seize on the threads.
You should use anti-seize on anything that threads into aluminum including spark plugs. Dissimilar metals (aluminum and steel as an example) will bind and the aluminum will gall and fasten itself to the steel bolt. Often a easy out will not solve that problem.
You should use anti-seize on anything that threads into aluminum including spark plugs. Dissimilar metals (aluminum and steel as an example) will bind and the aluminum will gall and fasten itself to the steel bolt. Often a easy out will not solve that problem.
Burning Brakes
Joined: May 2010
Posts: 941
Likes: 10
Your not a dummy! This is a age old problem. Leave drilling and easy outs for last resort. PB blaster- i heat and spray several times and let it sit overnite. Some machinist use candle wax. They heat the screw or bolt then touch candle wax on it and it draws in and lubricates.8Valve
Safety Car
Joined: Nov 2009
Posts: 3,973
Likes: 341
From: Adelaide South Australia
I use an impact driver with a 1/4" extension that i ground on the other end so the torx bit holder fits on, I have used this method a few times and got a torx bit off the manifold last week using it.
Thread Starter
Instructor
Joined: Jan 2011
Posts: 165
Likes: 0
From: Eureka Ca
Nope, bolt is not out yet. Yesterday I bought some PB Blaster, sprayed and let soak overnight. I also got a T45 socket that I will try first and I also got a left hand drill bit and a screwed up screw taker-outer as a back up plan B. Hopefully today if I get all my errands run. Keep all appendages crossed!