Best way to cut off fan clutch? Fan clutch bolt stripped.
 

A while ago I decided to replace the tensioner and tensioner shock, but the fan clutch bolt stripped.

I thought about using a die grinder but I'm unsure on if it can fit down in their. I'm looking to cut off the tail end of the water pump.


Surely a reciprocating saw will work but I don't want to spend too much.

Helps to know the year and model of the car you are working on.

So do you have the pump off or is it still on the engine? But by cutting off the clutch it will ruin the pump anyway so it must be off the engine yes.

Oh 1997 E300D

It's still on the engine, the water pump is impossible to remove with the fan and fan clutch on.

Don't the 606 engines use the T-55 Torx bit? How'd you manage to strip that out?

I thought they used the same one as the OM603? Uh oh.

Nevermind the above response.
From what I gathered original OEM where 8mm hex, but OEM replacements where Torx. The fan clutch and pump are original a far as I can tell.

Take a look at this..........it might give you some ideas:


https://www.2carpros.com/questions/mercedes-benz-300d-1997-mercedes-benz-300d-fan-clutch-removal

My mistake. When I upgraded my SDL to the 606 style clutch/fan, the bolt was Torx, I assumed they all were on the 606!


You have my deepest empathy on getting that bolt out. Mine was so seized it stripped out the TOOL, not just the bolt head! I have a thread on here somewhere about it. Clutch and water pump were wasted by the time I got it apart, I only wanted to save the fan blade.

Yeah looks like a cannibalism of the water pump is inevitable, I'll see if a die grinder can fit, if not, time to save for a reciprocating saw + blades.

Remove the water pump housing, the unit with the thermostat that the water pump bolts to. The bolts go sideways into block. The fan/clutch/pulley isn’t in the way.

Sixto
98 E320 wagon
02 C320 wagon

Hopefully this work, it'll save me from trashing parts.

Bumping thread, what's the easiest way to remove the sheared bolt? I have no idea how i'm going to remove it once the water pump housing is off.I don't have a vise to secure it with either.

I need to get this done because my shock tensioner is worn.

Unless I'm missing something really obvious why not just remove the radiator and/or the condenser?

You'd be looking right at the bolt and could utilize any of the standard bolt removal techniques, Ez-out, drill-out, weld a bolt onto the exiting bolt, ect. No need to destroy the water pump, clutch and buy a reciprocating saw. BTW using a reciprocating saw 1 inch from the radiator is a great way to pretty much guarantee you'll be removing the radiator anyways to replace it when your saw blade slips and nicks up a couple rows of highly fragile aluminum in the radiator.

It's been awhile since I've removed the radiator on an OM606 but as I recall it takes about 5 minutes.

I have a feeling attempting to drill it out will be useless, that thing is STUCK in there, plus the bolt is massive. Looking back at the SDL, it tooks ridiculous amounts of force to remove the fan clutch bolt when I did, that one didn't strip.

Tried EZ outs and lefts hand drill bits on mere valve cover bolts with failure. The more I look at it, the more sense it makes to just cut it off.

I have a spare water pump and fan clutch.

If you have a spare pump and clutch, why are you wasting your time trying to save that one? Hit the nearest trash can with it and save your sanity.