Rounded Bolt - Intake Plenum 3VZFE

[Hiro]

Sounds like you're in trouble...

3 options.

1. Easy-out. great if it works, totally shit if it breaks off in there

2. Attach allen key, apply welder, pull out bolt and throw away bolt + allen key

3. Call a mobile bolt removal specialist. I'd recommend trying #2 first, since a cheap allen key is a LOT cheaper than a mobile bolt guy

Last time I had to get a mobile bolt/thread guy in, it cost something like $80 including the call-out (he was in the area anyway) and the helicoil

[Duk]

I found this page pretty interesting and find the hammering technique often works.

If you can get vicegrips on there at all I'd try them again, and clamp it as hard as you possibly can before trying to turn it.

Hen

Always hit the bolt head with a hammer and dolly if it's been screwed into machined bolt holes, especially when screwed into aluminium. Tends not to be required when it's screwed into cast iron tho.

I highly recomend this as it's something we do very often where I work and there is not many places that makes for bastard bolts in machined /drilled and tapped holes than a steel works.

Hit that bolt head and then grab it with vice grips again. If it doesn't go, hit it again.

[crowncustom]

As what was said above with cutting a slot in it but instead of using a flat bladed screwdriver use an impact driver with a flat bit in it and hit the bejesus out of it.
Cheers Brett.

[CLG]

Drill the head of the bolt off, remove cam cover, grab the remaining exposed thread with a pair of multigrips and undo, buy replacement bolt, job done.

A speed wrench as shown above is also good, however only effective on larger type bolts (it cannot grip before the knurling on it's teeth), and I'd hazard a guess that if the torque used previously, flogged out the internal hex of the bolt, you certainly won't get enough torque through a screw driver and slot to remove it either!?!

[TERRA Operative]

And when you go to put it all back together, go get some Loctite silver anti seize (it's nickel based, so good for stainless bolts in alloy), it's in a little glue stick type tube from Repco etc, and give the bolts a wipe before they go in. They'll never seize again.

[ddeane]

I recently acquired a set of 'sockets' from gasweld that are designed for this problem. They are like a reverse easyout that grips the outside of the head of the bolt or nut as you undo it. It has a coarse lefthand drive thread inside the socket. Works a treat if you can get the tool onto the head.

Cheers Craig

[Cuts]

try some loctite freeze off spray on it too man.

[gerry.c]

Hi guys , first post but youve got to start some time!!

if the inhex bolt is not to badly damaged , wet the end of the allen key with some oil/spit then put some dirt on it and this will aid in gripping the bolt and you may be able to undo it. Valve grinding paste also does the same job.

[SillyCarS]

try some loctite freeze off spray on it too man.

this is good shit, we were trying to remove the end seal on a 10 ton hydraulic ram in th middle of the desert (drilling in coober peedy) and everything failed. then we hit it with that shit and cold whacked it with a chisel and she broke free

[Talasas]

I had this same problem once on my 4AGE. Ended up taking the head off and accidentally converting it to turbo in the process...

Top advice here though guys. My first suggestion 100% is if you can weld something to it, do so. Obviously make sure to let it cool before attempting to undo it.

[Pluto55]

Is this bolt been removed yet??
Is it still drivable? is it a beached whale?

If that you don't have tools or expertise to fix your self then get a third party to do it for you.

If you are going to get some one else to do it as you have a gut feeling you are not going to get it out without braking it or something else in the process.

Don't butcher it first let someone else work with a bolt not a nub of steel. The cost will be similar if you do nothing and ask for help. If they brake it and it takes them longer, they might feel guilty and help you out by charging you less.

PS. I like the weld and toss away option best. Find someone who can weld. engineers, panel beaters. probably do this for next to nothing if you can drive the car there.

[Razor]

Nah not yet, Had to put it back together again and havent had the time to try again.
Might just get someone to do it for me .