Any easy way to remove a stripped allen head bolt the bottom one on my vacuum pump when i went to remove must have been cocked or in bind or something rounded it out i'm hoping not to have to drill it only way i can think of is to remove the radiator and go thru there? anyone got ideas?

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2004 Infiniti G35 3.5L 6mt Coupe 73K miles 25.6mpg ytd
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1982 300D Turbo 231K 120hp? 28.1mpg YTD

So, the bolt hasnt been undone, the thread is still OK in the block, and the hex socket head is rounded out?

In this case, I would take a suitably sized El-Cheapo TORX bit and tap it into the rounded out hole. With a little luck, it will give sufficient grip to get the bugger out.....

Alternatively and more difficult would be to try a Mole-wrench on it

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Alastair AKA H.C.II South Wales, U.K. based member

W123, 1985 300TD Wagon, 256K,
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W114, 1975 280E Custard Yellow,
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Try going up an allen size if you can. If you can get any purchase on the bolt, be very gentle and it just might start turning. That is what i have always done. That bottom bolt is a pain in the butt.

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1979 240D with a 617 turbo diesel.

X2. I had to resort to the Vice Grips, after removing the AC compressor.

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...and clean the junk out of the hole(s) BEFORE you begin this job...or any job with hex head caps, i.e., fan clutch, engine mounts, etc.

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Easy. Buy a dremel and grind the head off, then use locking vice grips and remove whats left.

Next time, make sure the hole is clean and make sure it is seated very well before turning the rachet.

I think an appropriately sized easy out bit would tap in there and pop that sucker out without drilling.

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
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My drivers:
1987 190D 2.5Turbo
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Try the deck screw extractors you'll find at Sears. It worked for me on a stipped M6 socket head cap screw recently.

If you have enough access, use a hammer and small cold chisel kind of tangential to the head to start loosening the screw.

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1987 W201 190D

Tip:
When removing a pump from the junkyard, start with the bottom bolts in case they're already stripped. You don't want to remove all the easy ones on top only to find that the last two won't come out.

I have never tried it but some members have said those external Esie out rounded head bolt removers work on the Allen Head bolts. I have never tried this and do not know if there is enough room for them.

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84 300D, 82 Volvo 244Gl Diesel

Same thing happened to me, I was able to clean the head and tap the allen key in with a hammer then I turned it slightly clockwise, hammerd it again, then CCW and it came out.

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1984 Euro 300SDC, (4spd standard)
1986 Toyota Landcruiser Diesel HJ60 5spd X2

Gone but not forgotten (some sold, some stripped)
1983 300 SD, 1985 300 SD, 1983 240D, 1986 300 SDL, 1985 300 SDL, 1983 300 D, 1984 300 D, 1985 300SD, 1987 300 SDL, 1983 300 SD, 1985 300 TD Euro, 1983 380SEC, 1990 300 D, 1987 300D, 1982 300D, 1982 300D, 1994 E420, 1987 300 TD, 1987 300 D, 1984 300 D

Square Esie out might work.
Also some of the Allen tools have tips that have too much Radius (rounded) and there is not so much of the wrench area to grab onto the Bolt. If you think this is the case grind the tip of the Allen Tool flat.

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84 300D, 82 Volvo 244Gl Diesel

the torx trick worked....but I came up with extra washer cant remember if they're is a washer on bottom of piston and one on top or if the kit had extra one to go along with the nut on the rod that drives the piston ideas/help thanks?

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2004 Infiniti G35 3.5L 6mt Coupe 73K miles 25.6mpg ytd
2001 Green Audi TT 225 AWD Roadster 71K 6sp 30.9mpg >>STOLEN<<
1982 300D Turbo 231K 120hp? 28.1mpg YTD