How do I remove rounded allen bolts?!
Posted
#1583271
(In Topic #214888)
Settled In

I'm removing an engine of which the drive shaft allen bolts are rounding off… i have the right size allen key but they are all knackered… is there a quick and easy way of removing them??
Posted
Old Timer

are you sure you have the right tool? all mine have been triple square drive not hex head.
easiest way would be leave them on till the engine is out so remove hubs with engine, then cut heads off bolts with an angle grinder then when cv is off use grips to undo, shouldn't be that tight when cv is removed
easiest way would be leave them on till the engine is out so remove hubs with engine, then cut heads off bolts with an angle grinder then when cv is off use grips to undo, shouldn't be that tight when cv is removed
Posted
Settled In

Yea they are all hex head, i guess that is probably the quickest way… I'm guessing you'd have to lift the car off the engine to achieve it though?
Posted

Settled In

in the past I have used a bit of heat and tapped a socket over them to get them off cant remember size of socket though maybe a 13mm or 14mm need to be a tight fit knock on with a big hammer
works a teat but use a old socket and not the hex kind
works a teat but use a old socket and not the hex kind
Posted
Local Hero

The drive shaft bots are 12 pointed star drive, someone may of used the wrong tool to remove them.
You can get new bolts.
To remove you can try and hammer in a slightly bigger spline tool and hope it grips to undo the bolt or a big pair of mole grips and grab the bolt to undo.
Right tool looks like this.
http://www.ebay.co.uk/itm/SPLINE-BIT-SOCKET-SET-by-BERGEN-TOOLS-Triple-Square-12-Point-M5-M6-M8-M10-M12-/251980872965?epid=2043371760&hash=item3aab3afd05:g:4TYAAOSwWJhZX7SM
You can get new bolts.
To remove you can try and hammer in a slightly bigger spline tool and hope it grips to undo the bolt or a big pair of mole grips and grab the bolt to undo.
Right tool looks like this.
http://www.ebay.co.uk/itm/SPLINE-BIT-SOCKET-SET-by-BERGEN-TOOLS-Triple-Square-12-Point-M5-M6-M8-M10-M12-/251980872965?epid=2043371760&hash=item3aab3afd05:g:4TYAAOSwWJhZX7SM
1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 317,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.
Posted

Local Hero

Vice-Grip pliers, clamp them on the head and smack with a hammer they will break torque then use a TORXs hand they usually come out easily.
They are not allens they are 8mm Triple Square, and the bit is like 10 bucks over here, you have to be sure that you Tap it fully in to seat it before you apply torque to tighten or remove.
33ft/lbs is all you torque them to.
They are not allens they are 8mm Triple Square, and the bit is like 10 bucks over here, you have to be sure that you Tap it fully in to seat it before you apply torque to tighten or remove.
33ft/lbs is all you torque them to.
What do Divorces, Great Coffee, and Car Electrics all have in common?
They all start with GOOD Grounds.
Where are my DIY Links?
They all start with GOOD Grounds.
Where are my DIY Links?
Posted
Local Hero

He may well have hex head.
My new bolts that came with my shafts are hex headed. I was expecting 12 spline too.
I'd smack a socket over them.
My new bolts that came with my shafts are hex headed. I was expecting 12 spline too.
I'd smack a socket over them.
Posted
Local Hero

New bolts if needed?
Some CV kits come with new bolts in the box.
http://www.ebay.co.uk/itm/VW-GOLF-MK1-1-6-1-8-GTI-MK2-1-3-1-8-GTI-INNER-CV-BOLTS-SET-C181-/200806579563?hash=item2ec1013d6b:m:m1A3IxPMjugehjDRLWiG_VQ
Some CV kits come with new bolts in the box.
http://www.ebay.co.uk/itm/VW-GOLF-MK1-1-6-1-8-GTI-MK2-1-3-1-8-GTI-INNER-CV-BOLTS-SET-C181-/200806579563?hash=item2ec1013d6b:m:m1A3IxPMjugehjDRLWiG_VQ
1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 317,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.
Posted
Settled In

They were hex head… managed to hammer a 12mm socket over them and got them out. Just took a lot longer than originally planed… still only 3 engine mounts and it'll be out hopefully Monday lunch time it will be in the workshop ready to be stripped down. Thanks for all the tips and help guys!!!
Posted
Local Hero

Haha I literally just did this myself.
Luckily for me, it was only 1. Again 12mm socket hammered over it done the trick.
Luckily for me, it was only 1. Again 12mm socket hammered over it done the trick.
Posted

Old Timer

On my BMW 2002 I also stripped a few of the allen bolts.
I decided to just ground the head of them off and I was able to turn them loose by hand probably since the tension was removed from the whole bolt and the threads.
As long as it's not rust welded you should be fine.
Although I would suggest using a vice grip or a hammer and chisel to try and spin it loose first.
I decided to just ground the head of them off and I was able to turn them loose by hand probably since the tension was removed from the whole bolt and the threads.
As long as it's not rust welded you should be fine.
Although I would suggest using a vice grip or a hammer and chisel to try and spin it loose first.
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