how to take off damaged torx bolt from spark plug cover

shawny · Post by **shawny** » 01 Apr 2009, 22:40

It's a 97 850. I tried to remove the spark plug cover, and somehow damaged the torx bolt thread. Do you have a smart and economical way to remove the bolts? Do we have to keep the spark plug cover on the top of engine?

Thanks a lot,

Post by **Ozark Lee** » 02 Apr 2009, 06:14

I was able to pound in a torx bit the next size up. If that doesn't work I have heard of people cutting a slot in the head with a Dremmel tool and using a straight blade screwdriver.

They obviously need to be replaced with new once they are out.

...Lee

svendyensen · Post by **svendyensen** » 02 Apr 2009, 11:05

I had the same problem on my 98 V70. All but 3 of the scres came out without a problem. I used some PB Blaster on the 3 stuck screws, then used a screw extractor to remove 2 of them. One ended up breaking off just below the metal of the engine, so I just put the cover back on with one less screw. I also used all new standard bolts (hex head) that I got at autozone.

iselloil · Post by **iselloil** » 03 Apr 2009, 12:24

Wire brush you bolts and put a small amount of never sese on the thread

ChiNorm · Post by **ChiNorm** » 03 Apr 2009, 13:17

+1 for using a Dremel cutting disk to cut a screwdriver slot.

Good luck.

Post by **1997volvo850** » 18 Apr 2010, 12:54

Well, a very disappointing day of work on my Volvo 850. Spent last hour or so on one bolt.

5 of the 6 spark plug cover bolts came off with #30 Torx socket with very little effort.
First had to wire brush the tops to expose the Torx star pattern. Also applied
PB Blaster to all of the bolts.

Bolt number 6 was rusted to the point there was no recognizable star pattern.
Unable to extract with Torx 30 bit. Of course stuck bolt is in worst location, right rear
next to upper motor mount.

I used my Dremel tool to grind a slot into the head of the bolt. It holds a large screw driver
and I still can't budge the bolt. Not sure what to try next.

I will need some new spark plug cover bolts. I'm guessing they are available from the
nearest Volvo dealer. Are these bolts standard enough to be available at regular
auto parts store?

whoa · Post by **whoa** » 18 Apr 2010, 13:18

Drill the head out and forget about it. It's cosmetic and a dust shield. Put anti-seize compound on the bolts that do come out, like you do with spark plugs. You're not in so big a hurry that you need to go dealer. One bolt is enough for now, or drive it without it.

Post by **1997volvo850** » 18 Apr 2010, 16:43

Managed to get it out with a large screwdriver and crescent wrench. What a pain...

I guess I need to open up the spark plug cover more often. Maybe use anti-seize on the screws.

claymore850 · Post by **claymore850** » 18 Apr 2010, 21:43

Try to hit the lateral part of the head with a small cold chisel and a small hammer, in CCW direction to get some movement to head of the bolt..sometimes is the best way to remove seized bolts...remember to use you eye protection or better a face shield..

Post by **Hoov** » 18 Apr 2010, 22:56

shawny wrote:It's a 97 850. I tried to remove the spark plug cover, and somehow damaged the torx bolt thread. Do you have a smart and economical way to remove the bolts? Do we have to keep the spark plug cover on the top of engine?

Thanks a lot,

I had the same problem with the same bolt ... I'm not a patient person so I did the dremel tool, screw driver slot trick. Worked!
THEN When I took the cover off I realized this is just that, a cover. At that point I took care of the business I had there in the first place & then put the cover back on with the remaining bolts I had. (If the "slot thing" doesn't work & you have a rotary tool, just grind the head off so the cover hole will clear & take off the cover. You can then suturate the bolt w/penetrating oil & remove it w/vice grips cause what's left sticks up enough.
There is no "seal" or gasket problem here so we don't need the last bolt! LOL, I like things "pretty" so I covered the bolt hole with Bondo, sanded it & painted it black. Twenty minutes work, nobody will know & the cover is in place. (If anybody here would look, they would just smile, knowing the whole story instantly)
Don't stress! Don't spend money, adapt! hahaha.

Hoov