While replacing my motor mounts on Old Black (1985 300D turbo). I hit a big snag - the driver's side small fasteners(two on the edge, on the top) will not come out. Looks like the heads have been rounded off. I have tried cleaning, hitting the bit with a hammer to no avail. The ones on the pass. side came out with no problem.

Any ideas?

Thanks in advance,
Jason

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1985 300 D - turbo
258k miles and still ticking!
Black/palamino
Alda dustcap modification
Eastern NC -

How big are the bolts? Craftsman has these things you place on the bolt head (it will grip the bolt no matter how badly rounded off) and they are hexagonal on the outside so you can use a socket wrench or combo wrench or whatever and turn the bolt. Works great. I forget what they're called though.

Edit: They're called Bolt Outs. Think they're 20 bucks for a pack of 5 different sizes or so.

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1985 CA 300D Turbo , 213K mi

You might try a pair of vise grips as well. You'll have to replace the bolts anyway. Although it might be tough to get them in there and still have room rotate to get them out. But worth a shot.

I had a stripped bolt on the trans. my toyota pickup I ended up using vise grips to get it out.

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Sometimes a torx bit of just the right size can be hammered into the hole and provide enough bite to get it out.

I replaced all of the top bolts on the engine mounts when I did them this summer. I found exact replacements at Home Depot for about 60 cents each.

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Bob
'82 300D Petrol B-G Metallic

I have tried to JB-Weld in an allen driver in situations like that, but w/o success. What did work was to electric arc weld in a small allen driver into the socket. Its tricky, especially if working unside down, but as a measure of last resort, it does work.

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1982 300SD " Wotan" ..On the road as of Jan 8, 2007 with Historic Tags

it's raining here, so I won't go out and look at my car, but if there is enough room, a small pipe (stillson) wrench should do the trick.....I have a 6" one for removing the odd stud and rounded off bolts and such.....

also, as was mentioned those Craftsman Bolt Extractors, I think I have seen them sold in Lowe's (Irwin Tools)....work well......

always use lotsa penetrant.....and some heat, if possible to do.... and not create a hazard or local news item.....

heat, penetrant, cool, tap tap....repeat several times....try again......patience, some beer or whatever may be in order to prevent frustration....

SB

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Diesels:
'85 300D, "Max, Blue Benz", 155K, 27.0 MPG
'84 190D 2.2, "Eva, Brown Benz", 142K, 40.2 MPG
'77 240D (parts car)
'67 Eicher ES 202 Tractor "Otto" (2cyl, Air Cooled, 30HP)
Gassers:
'94 Ford F-150, "Henry", 170K (300 Six) 17.5 MPG
'85 190E 2.3, 148K....Parts Car
'58 Dodge W300M Powerwagon (Flat Fenders) Less than 10 MPG

Most helpfull thing I have found is removing the bottom bolt and raising the engine several inches. That allows you to remove the metal shield from the mount and gives you a bit more room to work in there. Then vise grips are my favorite. try taking off the tire so you can get in from the wheelwell, if you have not already.

I took a break from the mechanic work and went to the ECU/Marshall game. I will pick up the bolt or easy-outs and a good set of small vice grips and jump on it tomorrow.

Good tip on removing the heat shield. I have done that - the center section of the mount on the drivers side popped right out - I have taken a knife and cut away the outlining rubber.

Thanks again - this has been a bear!

Jason

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1985 300 D - turbo
258k miles and still ticking!
Black/palamino
Alda dustcap modification
Eastern NC -