Rounded start motor alan key bolt, idea's on how to remove??

[ralph350i]

Hi Guys
Well went to change the start motor this morning as have found the the top alan key rounded, any ideas how i am going to get this removed please as need to replace the starter.

thanks

[richtvr]

You can get bolt removal tools for this, I have a snap on set you drill the head out a bit then you put the extractor in the hole which has blades on it anti clock wise as you wind the piece out it digs into the bolt undoing it.

If your by Coventry you can borrow my set

[Wedg1e]

I'd be trying an impact driver with a long 1/2" extension and a chisel bit to see if I could crack it loose, it'd probably then unscrew by fingers. 'Course there may not be room to swing a hammer, but that's my first thought...

[gromit wedge]

You could try hitting a torx bit into the hole that's just larger than the hole and see if you can unscrew it. It's a long shot but it might work if the bolts not too tight. This method has worked for me in the past but it depends how tight the bolt is??

[ralph350i]

Thanks for your replies guys, as the starter did not work anyway, i thought i try replacing the solenoid from another starter i had and bingo, the only problem is its killing my battery, i put a 700ah of my transit and it killed it in 3 tries to start the car???? now it maybe that my transit has been sitting with little use for 4 months, so i,ll fully charge the battery and try again, hopefully that nut can wait for another day lol

Many thanks

[johny105]

drill the head off (if accesible ) and use mole grips or stud extractors

[The Hatter]

Are you using a metric allen driver? On my car the engine is all imperial fixings but the gearbox/starter is metric.

Might be worth trying a new metric bit of high quality. I've also found that grinding the tip off the metric driver helps to make sure you're biting right at the end of the internal socket head; and tap it in as best you can with a hammer.

Good luck; this bolt is a s*d.

[combine]

Not suprised about one of those bolts being 'tough' , I called a friend in with a industrial set of keys , the bh came out thank goodness, now got a lovely starter in protected by heat wrap as they get affected by the ridiculous position of the manifold.

[ralph350i]

Thanks Guys
If i have to remove i,ll take on board all you kind comments

Many thanks

[wooly350i]

Ralph,you need a set of turbo sockets available from good motor parts stockists,I've got a set and they'll undo any rounded off head so should be fine on an Allen bolt head,the head will be knackered after but if its rounded off who cares,my set are 3/8th drive and worth their weight in gold,we've even undone locking wheel nuts with them! Should cost about £30 or so but you'll always have them afterwards,john.

[ralph350i]

wooly350i said:

Ralph,you need a set of turbo sockets available from good motor parts stockists,I've got a set and they'll undo any rounded off head so should be fine on an Allen bolt head,the head will be knackered after but if its rounded off who cares,my set are 3/8th drive and worth their weight in gold,we've even undone locking wheel nuts with them! Should cost about £30 or so but you'll always have them afterwards,john.

Noted Wooly and thanks, another item on the list lol

[adam quantrill]

I drilled a hole through the bolt head and also took a socket which fitted over the head and cut some slots in it, then I passed a metal rod through the bolt head, plipped the socket over and it cracked open relatively easily.

It took about 4 drill bits to drill the head, mind!

Needless to say normal hex head bolts on there now...