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  #1  
Old 01-03-2002, 08:45 PM
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Help with flywheel bolt removal

I am trying to remove the hex head bolts on the flywheel connecting it to the crankshaft on my 1977 300D. Two of the hex head bolts are missing part of the side (the way I found them, it looks like they just dissolved away!) and the correct size Allen head wrench just spins freely in the head.

Unless someone knows a better way, I am going to remove the flywheel bolts by drilling them so the head comes off and then back out the shank with the threaded portion (I hope to use a pair of pliers, but I am ready to drill the shank to fit an easy out tool into then back out the remaining part of the bolt).

What is the approximate diameter of the shank on the flywheel bolt? The flywheel bolt is the waisted shank type that stretches when torqued and is smaller in diameter then the threaded portion of the bolt. I believe that I should use a drill bit just larger than the shank to remove the head and avoid contacting the side of the flywheel because the flywheel is balanced. I have fractional, metric, and numbered drill bits - so I have the correct size bit if someone can tell me the approximate size of the shank.

Also, how hard are the flywheel bolts? I have some good drill bits (Snap-On), but I can get harder drill bits if needed. I have seen that M-B uses some very hard metal for some parts/fasteners and I do not want to start the job only to find that I need better drill bits by finding out the hard way because I messed up using the drill bits I already own (my drill bits are sharpened properly) and, thus, make the job harder because I have to correct my mistake first and then use better drill bits.

Thanks,
Tom
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Last edited by tcane; 01-03-2002 at 09:12 PM.
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  #2  
Old 01-03-2002, 09:20 PM
Capt Kirk's Avatar
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I posted in Diesel Section, but I'll post here as well.

You could JB weld a Allen Head wrench to the bolt.

Or you could just use some Vice grip pliers and try turning the bolt. That's what I had to do on my old VW. I had over tightened the flywheel bolts, so when I turn the car on the flywheel broke free. I had to go back in and take out the remains of the bolts using Vice Grips. It was a pain in the butt, but I finally got them out.
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  #3  
Old 01-03-2002, 10:23 PM
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I have done this with good success. I use a hammer to drive a socket of the appropriate size over the outside of the bolt head. Then simply remove the bolt. You must then pound the bolt out of the socket. Sometimes you need to use a SAE size on the metric allen head bolts.
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  #4  
Old 01-04-2002, 04:57 AM
Neil Eglintine
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Drill sizes

Don't try a large size straight away. Start small, which will help you centre on the bolt itself. Then increase the drill size in steps till you drop the head off. Dont rush this, new flywheels and cranks cost a lot!

The damage to the bolt heads sounds like they were over tightened and suffered fatigue.
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  #5  
Old 01-04-2002, 07:59 AM
LarryBible
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If you cut off the bolt head, the tension will be relieved and once the flywheel is out of the way, you will be able to remove the remaining stud with your fingers. Been there, done that.

Good luck,
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  #6  
Old 01-04-2002, 09:25 PM
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Success!!

Thanks for the comments and suggestions everyone! As it turns out, 5 more flywheel bolts were also bad - making 7 out of 12 bolts needing special procedures to remove them. I drilled them out, basically. I wrote a detailed reply in the Diesel Forum about how I did it - so go read that post for more details. I will say it was more effort than just drilling.

Larry: I know what you mean, I've been there and done that myself - it is a very bad movie, not the worst, but plenty bad enough!

Tom
__________________
America: Land of the Free!

1977 300D: 300,000+ miles

American Honda: Factory Trained Technician & Honor Grad.
Formerly:
Shop Foreman;
Technical Advisor to Am. Honda;
Supervisor of Maintenance largest tree care co. in US for offices in Tex.

Last edited by tcane; 01-04-2002 at 09:30 PM.
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