Best Strategy for Removing Stripped Torx on Spk. Plug Cover?

SkyVolvo · Post by **SkyVolvo** » 27 Mar 2010, 23:05

Hey,
So today I decided I didn't have enough work to do on my 1994 Volvo 850 Turbo. To spice things up, I stripped one of the T-30 bolts on the top of the spark plug cover. See?

I was wondering what strategies have worked best for other people. It's stripped totally clean - no purchase at all, and there's not a "next size up" option because the next size is T-40, way too big. I already tried gluing the T-30 socket into the bolt, applying a little penetrating oil to the bolt, and then trying to break it free, but to no avail.

What other solutions do you think would work well, given the potentially sensitive location of the bolts?

Thanks for the help...

Post by **JDS60R** » 27 Mar 2010, 23:32

Several methods can work . Here are a few.
Start with a spray of penetrant to help.

1. Use a dremel and grind a slot across the head. remove with flat blade screwdriver
2. Use the welder and weld a tool or bolt to it.
3. Use some JB Weld and epoxy a tool or bolt on - let it dry for 24 hours then remove.
4. Take a chisel and a hammer and whack the thing off at an angle to the head. (driving the chisel in at an angle to turn the head and remove the bolt.

Make sure to replace it once off. A little antisieze and light torque go miles on those bolts.

XxJenoxX · Post by **XxJenoxX** » 27 Mar 2010, 23:43

I believe my buddy used the chisel and hammer method on mine. And the antisieze is IMPERATIVE to this one. The way the expansion and everything works between the torx, aluminum, and plastic, you're pretty much screwed with out it. (heh)

If you're like me and don't have very many tools or much patience, and you have a decent pair of needle nose pliers....you can try that. Don't know if you'll be able to get enough torque or a good enough grip, though. And when you get new torx screws, go to the yard and get a ton of them! Those stupid things are all over these cars, many of them the same size as those, and they're not that hard to strip. Good to have extras on hand.

Post by **charlyW** » 28 Mar 2010, 03:07

SkyVolvo wrote:Hey,
So today I decided I didn't have enough work to do on my 1994 Volvo 850 Turbo. To spice things up, I stripped one of the T-30 bolts on the top of the spark plug cover. See?

I was wondering what strategies have worked best for other people. It's stripped totally clean - no purchase at all, and there's not a "next size up" option because the next size is T-40, way too big. I already tried gluing the T-30 socket into the bolt, applying a little penetrating oil to the bolt, and then trying to break it free, but to no avail.

What other solutions do you think would work well, given the potentially sensitive location of the bolts?

Thanks for the help...

These are only small bolts with large heads so dont get too violent or you could make things worse. As previous poster said either cut a slot into the top or a pair of needle nose pliers should get it moving enough for you to remove it.

KRUZNBY · Post by **KRUZNBY** » 28 Mar 2010, 14:38

Just use a bolt extractor. When you turn it to the left, it drills into the head of the bolt. You don't need a drill, just you use ratchet. I had the same problem the last time I had to remove the cover. It only took a minute to get the screw out.

EddieH · Post by **EddieH** » 28 Mar 2010, 15:05

One thing that has worked for me, is valve grinding compound. Spray penetrating oil on the seized bolt and let it soak in. Then take and put some valve grinding compound on the end of your torx bit (cover the entire end really good). A few blows with the hammer on the torx bit will help also. The valve grinding compound will help grip the sides of the frozen screw and aid in getting it out. Good Luck!!

Eddie

Post by **Ozark Lee** » 28 Mar 2010, 20:26

The spark plug cover bolt heads on my son's car were very rusted out and they stripped out just like yours. I just pounded in the next higher size torx bit in the torx kit, medium force with a hammer, and got it to bite well enough to get the old bolt out. I had already ordered a new set of bolts, they are cheap.

...Lee

dtropnevad05 · Post by **dtropnevad05** » 28 Mar 2010, 22:13

As a Tool and Die Maker I have removed hundreds of striped bolts. The first thing I do is soak it down with Kroil penetrating oil and let it sit for an hour. Then I use a die grinder with a small cut off blade and cut a slit across the head. Then you can use a flat head screw driver to remove the bolt, if it still won't budge get a small punch insert it into the torx pocket and strike it using a medium blow with a hammer. That should do the trick, if you don't have a die grinder and cut off blade then use a small punch with a sharp point make a indent about half way out to the edge then tap the bolt out. Tip the punch at about a 45* angel and using lite taps in a counter clockwise direction remove the bolt.

Hope this helps you out.

Don

850 Turbo1 · Post by **850 Turbo1** » 28 Mar 2010, 23:25

I thought I was really stupid for stripping mine when I was replacing spark plugs a few months ago...I searched this forum and didn't find anyone experiencing my problem. I feel a little better now...lol..

I've tried 2 methods.

My mechanic took a flat head and hammered it into the bolt...he had a steady(experienced) hand...got it out in 1.5 minutes

My friend took a larger T socket and hammered it into the bolt....and out it cam...3 minutes.

Both of those methods work....I would start with the latter though...

dtropnevad05 · Post by **dtropnevad05** » 30 Mar 2010, 06:26

Here's a heads up, all flat head bolts only have .032 of material at the bottom outside edge of the socket. So you might want to careful when pounded on them, they tend to brake easily, I know. This will not be an issue if there is not any corrosion around the threads. If there is corrosion you just made a tough job tougher and will now have to drill it out. This is not a fun time at all.

Don