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#1
06-12-2009, 09:47 PM
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ideas to remove semi rounded allen bolts
I am currently doing the upper oil pan on the 77 because its leaking real bad. I got almost all them out except for the ones at the tight places where I cant use my plastic hammer to make sure the allen socket is in all the way. They arent completly rounded yet as i can take my a 5 and 6 mm allen wrench and put it in there. However I cant put on any real pressure to remove them otherwise they began to slip.
I was thinking of brazing the socket in place. Any other ideas?
__________________
1986 300SDL, 211K,Dealership serviced its whole life 1991 190E 2.6(120k) 1983 300D(300k) 1977 300D(211k) 
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#2
06-12-2009, 09:58 PM
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JB weld a junk allen wrench in and then remove the bolt.
__________________
1985 300TD Turbo Euro-wagon 1979 280CE 225,200 miles 1985 300D Turbo 264,000 miles 1976 240D 190,000 miles 1979 300TD 220,000 GONE but not forgotten 1976 300D 195,300 miles 1983 300D Turbo 175,000 miles http://i42.photobucket.com/albums/e3...e485-1-2-1.jpg
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#3
06-12-2009, 10:11 PM
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Valve grinding paste might help if the head is not too far gone. The grit gives the tool a better grip.
__________________
Palangi 2004 C240 Wagon 203.261 Baby Benz 2008 ML320 CDI Highway Cruiser 2006 Toyota Prius, Saving the Planet @ 48 mpg 2000 F-150, Destroying the Planet @ 20 mpg TRUMP .......... WHITEHOUSE HILLARY .........JAILHOUSE BERNIE .......... NUTHOUSE 0BAMA .......... OUTHOUSE
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#4
06-12-2009, 11:56 PM
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How about an easy out. The threads go in the opposite way you want to turn the bolt, so it gets tighter as you turn counter clockwise to loosen the bolt.
__________________
85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale** 84 300D 333K Black (The Velveteen Rabbit) 0-60 in 14 seconds 00 Toyota Sienna 208K (Sold) 15 Subaru Outback 43K 11 Subaru Outback 67K 98 Ford Taurus 100K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now. 30 Model A Ford 2 Door Sedan (Sold) 0-60 in . . . Never reached 60 
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#5
06-13-2009, 09:50 AM
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i do have some easy outs, im also going to try to put in a slight over sized allen key. If that dont work Ill put in a slot on the head of the bolt and use and impact driver bit turned by a raquet.
__________________
1986 300SDL, 211K,Dealership serviced its whole life 1991 190E 2.6(120k) 1983 300D(300k) 1977 300D(211k)
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#6
06-13-2009, 10:44 AM
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Umm . . .
Quote:
 But . . . a "Ratchet" just might work . . .
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#8
06-13-2009, 11:06 AM
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move up to a slightly larger, possibly SAE wrench
__________________
 1987 560SL85,000 miles Meet on the level, leave on the square. Great words to live by Were we directed from Washington when to sow and when to reap, we should soon want bread. - Thomas Jefferson: Autobiography, 1821.
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#9
06-13-2009, 01:30 PM
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Grind the allen key
Use a slightly larger allen key and grind the flats to a slight taper so they will wedge into the bolt head. Drive it in with a hammer blow carefully & turn. A pin punch blow to the inside of the allen head bolt will help to crack it loose. Use brake cleaner and compressed air to clean out the dirt from the hole. A small screwdriver will pick loose the hardened stuff. Cheers Dan
__________________
It's always something simple 91 300D 603.960 (from japan) 194K 92 Toyota Diesel Landcruiser HDJ81-t 116K 02 Golf TDI new head courtesy of PO 87 300D 97 BMW 525 TDS Wagon 5spd bunch of Onan and other diesel generators
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#10
06-13-2009, 03:45 PM
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Quote:
__________________
2004 Infiniti G35 3.5L 6mt Coupe 73K miles 25.6mpg ytd 2001 Green Audi TT 225 AWD Roadster 71K 6sp 30.9mpg >>STOLEN<< 1982 300D Turbo 231K 120hp? 28.1mpg YTD
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#11
06-13-2009, 04:12 PM
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get an external easyout socket set. craftsman makes a set as do most of the tool suppliers. hammer it onto the head of the bolt, and use ratchet...
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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread "as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do! My drivers: 1987 190D 2.5Turbo 1987 190D 2.5Turbo 1987 190D 2.5-5SPEED!!!  1987 300TD 1987 300TD 1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!
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#12
06-13-2009, 05:39 PM
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allen heads
Might not be able to get into the hard to get at allen heads with an external easy out. Not much room around the lip of the oil pan. Cheers Dan
__________________
It's always something simple 91 300D 603.960 (from japan) 194K 92 Toyota Diesel Landcruiser HDJ81-t 116K 02 Golf TDI new head courtesy of PO 87 300D 97 BMW 525 TDS Wagon 5spd bunch of Onan and other diesel generators
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#13
06-13-2009, 09:08 PM
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i was able to able to get an irwin easy out in there, even the tight spots. While I was in there I cleaned the thick crude on the oil pan, inspected my oil pump and found it be worn, a gasket broken. So I took another one I had that looked better, cleaned it out. Also found some metal fragments in the screen of the oil pump
 Also got really dirty too 
__________________
1986 300SDL, 211K,Dealership serviced its whole life 1991 190E 2.6(120k) 1983 300D(300k) 1977 300D(211k)
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