[buzbox]

Well that sucks... Is the first thing I said when a head bolt had rounded. And of course, It's the last one I need to take off before removing the head and take the block in to get worked on.

I don't think Easy outs would be the answer for this one, I don't think a larger sized hex driver bashed in place would work either, It's waay to tight for the grinder, A bolt welded to it wouldn't be strong enough to remove it.

The only thing I can think of it drill out the head of the bolt, Or take it into the engine reco guy's and say, here you go.

Any ideas?

[JrZook]

Had one like that. Ended up just drilling the head off.

[shep]

Use a single hex socket.

[buzbox]

shep wrote:

Use a single hex socket.

Yep that's what I have and used, but no luck, It's well rounded.

[ball]

get a big nut (7/8 or 1 inch) and bash it over the rounded head. Weld nut to bolt and let cool completely before trying to remove.

[atari4x4]

sounds like a good excuse to buy more tools.

http://www.bestpricepowerhandtoolsonsal ... r_Base_Set

[Built4thrashing]

they look interesting

[atari4x4]

i've seen them work on the most rooted bolt head you could imagine, a good option if you don't have easy access to a welder to give balls technique a go.

[superduki]

atari4x4 wrote:

i've seen them work on the most rooted bolt head you could imagine, a good option if you don't have easy access to a welder to give balls technique a go.

Yep we use the Irwin brand ones at work all the time. Works 9/10 times. Still amazes me how they grip so well!

[Joe]

atari4x4 wrote:

i've seen them work on the most rooted bolt head you could imagine, a good option if you don't have easy access to a welder to give balls technique a go.

Pretty sure Ninjamoses used one of them on the motor he was pulling down and it worked for him

[KEENSY85]

atari4x4 wrote:

sounds like a good excuse to buy more tools.

http://www.bestpricepowerhandtoolsonsal ... r_Base_Set

nice

[royce]

The socket head bolts? get something sharp in and clean all the shit out of it and youll get some fresh hex to work on, bash the bit in with a hammer

[ninjamoses]

atari4x4 wrote:

i've seen them work on the most rooted bolt head you could imagine, a good option if you don't have easy access to a welder to give balls technique a go.

x50000000

Joe wrote:

Pretty sure Ninjamoses used one of them on the motor he was pulling down and it worked for him

Certainly did, was in the same situation as you buzbox. Last head bolt refused to budge even with a single hex impact socket etc. Irwell bolt grip in a rattle gun had it off in 2 seconds flat. Almost laughable how easy it was. Got mine from bunnings, think the 5 pack goes for about $50. I've been meaning to go buy the second half of them so I have the full set as they are that awesome.

[buzbox]

thanks heaps guys.

I'm sure bunnings won't stock them, but I'll pop out to my faviroute specialised tool shop in my lunch break, If that doesn't work I'll definitly give it the balls technique.

At least it's something Ii'll most probably use again.

[atari4x4]

my 2 local bunnings stock them.

[Scales]

i got a set of irwans too, best sockets ever!
bought the "base" set from mitre 10, and ordered the add-on pack from amazon.com after i discovered how awesome they are. (the whole set is in 2 different packs, as you can see in the pic with the case, the cardboard bit comes out with room for another 5 sockets)

[jdk81]

After reading this thread, with so many reviews Im thinking of giving these a whirl.

http://www.irwin.com/tools/screw-bolt-e ... strial-set

Now i'll just try to find the best price.

[defibros]

Any tools or ways to remove a rounded front diff nut?

[abclarke]

You talking about the plugs?

[defibros]

Yeah my front diff drain plug is rounded . Any tips ?

abclarke wrote:

You talking about the plugs?

[Zook_Fan]

Before you attack the drain plug get the fill plug out first. Not being able to drain the diff can be a pain, not being able to fill it means the car is stationary. The fill plug you pretty much have to weld a nut too. You don't have much option because there is nothing to grip.

[defibros]

Thanks for the tips . I don't have much options do I

Zook_Fan wrote:

Before you attack the drain plug get the fill plug out first. Not being able to drain the diff can be a pain, not being able to fill it means the car is stationary. The fill plug you pretty much have to weld a nut too. You don't have much option because there is nothing to grip.

[zukmeista]

Try this idea-http://auszookers.com/forum/viewtopic.php?f=17&t=6789

[buzbox]

defibros wrote:

Yeah my front diff drain plug is rounded . Any tips ?

abclarke wrote:

You talking about the plugs?

The thing I would do is drill a hole and use an easy out. I've tried the chisel technique on a diff plug before without good results.

Also I bought those threaded bolt sockets, It gripped quite well but it just couldn't quite shift the head bolt (or I was being too lenient) So I just took it into the engine reco place for them to deal with before I did more damage.

[sando]

defibros wrote:

Yeah my front diff drain plug is rounded . Any tips ?

abclarke wrote:

You talking about the plugs?

As already stated make sure you can get the fill open. With the drain buy a new plug as the one in there will be stuffed. I presume your drain requires a 3/8drive extension to undo it? If it does then go to supercrap and buy a crappy short extension. If you are good with a welder then weld the extension in, allow for it to fully cool then get a ratchet and undo it. The heat from the weld will loosen it.

[atari4x4]

sando wrote:

defibros wrote:

Yeah my front diff drain plug is rounded . Any tips ?

abclarke wrote:

You talking about the plugs?

As already stated make sure you can get the fill open. With the drain buy a new plug as the one in there will be stuffed. I presume your drain requires a 10mm square drive to undo it? If it does then go to supercrap and buy a crappy short extension. If you are good with a welder then weld the extension in, allow for it to fully cool then get a ratchet and undo it. The heat from the weld will loosen it.

fixed...

using a 3/8th drive in the drain plug is why it's been rounded out

[TheOtherLeft]

buzbox wrote:

defibros wrote:

Yeah my front diff drain plug is rounded . Any tips ?

abclarke wrote:

You talking about the plugs?

The thing I would do is drill a hole and use an easy out. I've tried the chisel technique on a diff plug before without good results.

Also I bought those threaded bolt sockets, It gripped quite well but it just couldn't quite shift the head bolt (or I was being too lenient) So I just took it into the engine reco place for them to deal with before I did more damage.

This might work for diff plugs:

http://www.irwin.com/tools/screw-bolt-extractors/hex-head-multi-spline-screw-extractors-522532-series