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  #1  
Old 02-17-2014, 11:22 AM
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Rounded out Ignition Coil Bolts

So long story short I went to replace an ignition coil and found that the hex pattern in the bolt head was almost rounded out so my 5mm just turns inside the bolt without much contact but not enough to get the next size in. Any ideas on a tool to get these out and what the part number is for replacement bolts once I get them out, the space is limited on a few of these bolts.
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Old 02-17-2014, 12:35 PM
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The fasteners are not hex but torx unless someone switched them. If damaged too badly then there are screw extractors. I have not personally used them but generally you drill a hole and the extractor has left hand threads so it tightens as you remove the damaged fastener.
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Old 02-17-2014, 12:45 PM
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You are correct they are torx not hex, my bad. Does any one know the replacment to these torx.
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Old 02-17-2014, 12:50 PM
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I have a lot of luck with Harbor Freight Extractor on 6mm allen head bolt. Never try 5mm but the extractor comes with quite a few sizes. I do not need to drill a hole, just pick the right size and slightly hammer it into the hole. It works every time.
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Old 02-17-2014, 01:05 PM
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There are also external extractors that grip the outside of the screw head.
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Old 02-17-2014, 01:42 PM
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I believe the fasteners are recessed so I don't think an external would work.
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Old 02-17-2014, 01:45 PM
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Quote:
Originally Posted by mmcfearin View Post
You are correct they are torx not hex, my bad. Does any one know the replacment to these torx.
Replacement? Try seeing if a T30 will catch. Probably easiest to get replacements from a dealer.
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Old 02-17-2014, 01:49 PM
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Quote:
Originally Posted by RichardM98 View Post
I believe the fasteners are recessed so I don't think an external would work.

No my torx are not recessed. Have a brand recommendation and any idea on finding replacement torx? Thanks for all the help guys.
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Old 02-17-2014, 03:19 PM
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I've had a lot of success with this set: Craftsman 5 pc. Power Bolt-out® Set - Tools - Hand Tools - Tap & Dies & Sets ... I know I've used the largest size to remove 6 mm T-27 panhead torx screws. The shaft allows for some degree of access to obstructed or recessed areas.

There's also a new type of extractor out there that uses a variable-speed drill: Sears.com -- I've seen infomercial demonstrations of something similar and it looks quite effective. Best of all, it eliminates that hazard of drilling out a bolt, inserting a spiral "easy-out" and then breaking the tool off in the hole.
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Old 02-17-2014, 04:06 PM
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Quote:
Originally Posted by Maki View Post
I've had a lot of success with this set: Craftsman 5 pc. Power Bolt-out® Set - Tools - Hand Tools - Tap & Dies & Sets ... I know I've used the largest size to remove 6 mm T-27 panhead torx screws. The shaft allows for some degree of access to obstructed or recessed areas.

There's also a new type of extractor out there that uses a variable-speed drill: Sears.com -- I've seen infomercial demonstrations of something similar and it looks quite effective. Best of all, it eliminates that hazard of drilling out a bolt, inserting a spiral "easy-out" and then breaking the tool off in the hole.
Thnaks so much now I just need to find the replacement bolts.
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Old 02-18-2014, 05:59 AM
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Recommend buying replacement bolts from your local MB dealer. They will be high quality bolts so you will avoid a problem when removing them next time.
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Old 02-18-2014, 11:34 AM
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They are not that tight on the coils usually...you may be able to grab it with an extractor socket or even with a pair of good vice grips clamped real right on the head.
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Old 02-18-2014, 01:56 PM
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the way i remove rounded out allens and torx bolts is find a larger one and tap it in then hit it with an impact, you can also try tapping a tripple square into it, if all else fails then use an extractor. This is the set I have EXDL10, Extractor Set, Left Hand, 10 pcs.
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