Rounded Bolt - Intake Plenum 3VZFE

[Razor]

Hi

Was going to replace my 3VZFE's rocker cover gasket and got stuck on 1 of the 2 10mm Allen type bolt. It was stripped before I even started so the previous owner tried removing it before.

How do I remove this bolt now that I cant use an allen key to undo it.

File the sides to make a flat area for a spanner?

One of the bolt was extremely tight but got it off anyway.

Im worried even if I file the sides it might just as well round off being too tight.

Any suggestions?

[Smokey228]

cut a slit across it for a large flat head screw driver?

The safest way is to tak an extension to it and than wratchet it off that way, i suppose you could also tak a nut to it so you dont ruin your tools?

Cheers,
jase

[Razor]

I think it will be difficult for a screw driver as the other was extremely tight had to use a cheater bar
once this is off I will be replacing them with a normal hex head bolt

[w0n0matic]

is the head exposed to grab at?
use a set of locking pliers (vice-grips) to get it off..

[Razor]

its got a 10mm Allen type round head

there's no room to grab the head with a vice grips ( I tried already) and it just strips the head as its very tight

[litldv8]

belt a torx bit into it - i think that they are only alloy and the jolting from hitting the bit in should loose it a bit. if you dont like the sound of that use a small cold chisel and a LIGHT hammer to tap it around like trying to remove the bolts from a ignition lock
neil

[Razor]

I've tried the torx bit as well just rounded it again

[Draven]

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

[Razor]

I think I'll try filing 2 sides so I can use a spanner and a cheater bar
as I dont have a welder
then if it doesnt work I'll call a bolt removal specialist

[neal]

Can you get a file to it so you file the side flat and get open ender or the ring spanner on it.

Failling that hammer a 9mm ring spanner onto it, ans see if it that grips and turns.

Failing that buy a tap and die set. drill down the middle of the bolt, use tap and die set remove bolt and replace with a new one.. if you stuff up the thread on the head helicoil it, bare in mind this step/bolt could cost you up $50.00 if you don't have the tools.

[neal]

Draven: number two is actually a brilliant idea. i'll keep that in mind for sure

[Hen]

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

[c2888]

I did this once whilst cutting my teeth at the wreckers :s

Get a big drill bit and drill through the guts taking the head off, try to clean up as best you can before removing the plenum to avoid bits of metal falling into the inlet runners. Once the plenum is off you should be able to turn the remains with a set of visegrips, if it doesn't squirt some penetrating oil around the base and let it work it's way down.

Don't try ezyouts, they WILL break. 15 years of heat cycling and a corrosive bond has that sucker in tight.

Or call the broken bolt guy, less headache, drink beers as you watch him remove the bolt

[JetspeedCamry]

If you use vice grips, then as suggested, file the edges down first flat. The work a hell of alot better when there not spinning around on a smooth round surface and actually have something to grab onto. If that's look at failing (don't try a spanner then as it def. won't work)), the welding trick is the last resort. Just mask all around the area with masking tape so you don't mark the cover with spatter.

[Shifty]

If there's no access it won't help in this case, but I've found that a "speed wrench" is an invaluable tool for undoing rounded nuts. The harder you try to undo the nut the tighter they grip.