Stripped Torx bolt head

[Krolroger]

Hello folks,

I am replacing the polybelt tensioner damper on my M102 (2.3) engine. I got the idler wheel off OK and applied a Torx 30 bit to the retaining bolt at the top of the damper. Unfortunately the tool was not of the required quality and I shredded the head.

I'm slightly at a loss as to what to do next. I don't want to pull the whole tensioner assembly but drilling the bolt out might prove tricky without removing the radiator.

What would a professional shop do?

(For readers in the UK, this star (Torx compatible) bit came from a high street chain better known for selling bicycles and is stated to be of professional quality. Well, the splines bent under firm hand pressure from a 3/8 drive....)

Thanks for any help.

Krolroger

[Kestas]

One method is to grind the head off with a dremel. This would allow you to remove the part, then you have more room to deal with the stubborn fastener.

On the minus side, this leaves you with the problem of removing the fastener by gripping only the shank.

[RickM]

A couple of methods for removing fasteners are:

Use a dremel or disc cutter and cut a slot into the head of the fastner. This will allow you to use a (hopefully large) flat blade screwdriver to remove.

Weld a large nut onto the stripped head. The weld may have to be on the inside of the nut. You can then use a wrench or a socket to remove.

Use of heat (torch), PB Plaster and/or tapping the fastner will help things along when using the abovementioned methods.

[jriewer]

Take a smaller socket that bareley fits over the bolt head, Use a socket that has multiple small teeth inside of the socket instead of the ones that have a six sided cutout. Put an extension on the socket if your can, and then hammmer the socket onto the head of the stripped bolt. Pound it on good. Once its on tight, use your ratched to unscrew the bolt. Works like a charm.

[Krolroger]

Thank you all. I think a Dremel drill/grinder is probably the way to go. As I'll have to buy one, should I get a 100 watt tool, or will the lower powered ones suffice for a job of this sort?

Cheers,

Krolroger

[RickM]

The smaller Dremel will probably be fine. Just might take longer.

[Kestas]

I found better luck using the thin cutting wheel as opposed to the small grinding wheel to remove metal, probably because metal loads up on the grinding wheel. It feels just like doing dentistry. See what works for you.