The 12 point 10mm bolts holding my axle shaft to the rear end of my 190e are all completely stripped out ( my new 12 point bit spins by hand) so how do I get the bolts out? I don't think I can get a grinder in close enough and I would think the bolt heads are to tough to cut even if I could get a saw in there. Anyone had sucess removing these bolts?

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85 300 SD ~ 115K
82 500 SEC Euro ??K
78 450SL 164K

Is there enough room to get a "Bolt Out" type socket on the OD of the head?

This is the TYPE of tool I'm talking about.

Craftsman Bolt-Out Damaged Bolt/Nut Remover Set Reviews - Craftsman Community

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'84 300SD sold
124.128

If that does not work.
Drill the heads off, and replace the screws.


.

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1985 300SD
1983 300D
1984 190D
2003 Volvo V70
2002 Honda Civic

https://www.boldegoist.com/

Grind off the heads, pull the joint out enough to get a vicegrip on the now untensioned bolts.

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Hanno
'79 6.9 Sold (after 27 years)
'83 280SL, 5 spd.
'94 E320 Sdn. 5 spd conversion
'02 E320 Sdn.(on loan to mom!)
'87 300E (5 spd. conversion) Sold
'05 E500 Wagon

Use one of these bits. They can be found in specialty fastener shops and some welding supply houses. I've destroyed the face of a MB ignition switch with them so I'm promise no bolt head will slow it down. Use a high speed drill and cover your eyes. The bits of metal are tiny almost a spray of glitter.

These grinding bits come in different sizes and shapes and with various shaft lengths. I paid $28 dollars for the first one I bought five or six years ago.

They are not as fast as a grinder and don't throw off sparks.

Attached Thumbnails

 

Cutting them is still gonna leave a loc-tite-ed bolt in the flange and you won't be able to move the axle the 3 inches outboard you'd need to get them off. Use the external type bolt extractor.

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90 300TE 4-M
Turbo 103, T3/T04E 50 trim
T04B cover .60 AR
Stage 3 turbine .63 AR
A2W I/C, 40 LB/HR
MS2E, 60-2 Direct Coil Control
3" Exh, AEM W/B O2
Underdrive Alt. and P/S Pulleys,
Vented Rear Discs, .034 Booster.
3.07 diffs 1st Gear Start

90 300CE 104.980
Milled & ported head, 10.3:1 compression
197° intake cam w/20° advancer
Tuned CIS ECU
4° ignition advance
PCS TCM2000, built 722.6
600W networked suction fan
Sportline sway bars
V8 rear subframe, Quaife ATB 3.06 diff

Drop the diff with axles for better access and results. It is a lot of work but you will be able to get at everything much better. I have had my jollies with these bolts and ended up with a buggered up rotator cuff for more than 6 months. Cheers Dan

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It's always something simple
91 300D 603.960 (from japan) 194K
92 Toyota Diesel Landcruiser HDJ81-t 116K
02 Golf TDI new head courtesy of PO
87 300D
97 BMW 525 TDS Wagon 5spd
bunch of Onan and other diesel generators

Thanks for all of the suggestions. I'm traveling this week but will sort out which to try soon.

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85 300 SD ~ 115K
82 500 SEC Euro ??K
78 450SL 164K

if all else fails-

sawzall halfshaft or break out the gas axe (oxyacyletene), cut halfshaft in 1/2 (I guess make it a 1/4 shaft ) then remove c-clips from diff - problem solved.

You lose your core charge, that's it. Save hours of BS tho.

rjp

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03 540I (GAK!!)
81 280E (W123)
70 LeMans Sport with pissed off Poncho 462"
1989 Silverado Step Side (under the knife- complete restomod)