How to remove a bolt with a "rounded/stripped" head on it? PLUS AOD TV Line pressure adjustment

[markinms]

I'm in desperate need of suggestions how I can [try to] remove a bolt that has a rounded/stripped head on it.

The bolt goes to the TV Pressure Port on my AOD transmission. It's in a very confined space. I've tried sockets, bolt removers, and vice-grips. All of these just caused more damage. The bolt head is now totally rounded.

Any suggestions would be greatly appreciated. I dread the thought of removing the trans just to remove this bolt.

On a another, yet related topic, has anyone had good luck adjusting the AOD TV Cable without using a pressure guage? If so, would you please share the procedure you followed?!

Thanks for any feedback!
Mark

 

[Dirtman]

 

[RonD]

+1 ^^^ these work well

But if bolt is not moving then it will most likely snap off the head
If possible heat the bolt and then cool it with compressed air or ??
Heating expands the metal of the bolt, then Rapid cooling shrinks the bolt and can break it away from threads that are holding it

But if it was cross-threaded then it will most likely have to be drilled out, use left handed drill bit in reversible drill

 

[Curious Hound]

Don't forget to curse at it.

Sometimes a hammer and punch, if you have room.

Scrub forward to the 1:30 point in this video and start there.

 

[markinms]

I tried using a bolt remover like the one shown above. Not enough bolt head to hang on to.

Heating the thing sounds like a good possibility. I can get a small torch up to the bold. The trans housing is aluminum; should that make any difference?

Video was very informative. Gave me an idea on something to try.

Thanks

Mark

 

[RonD]

Aluminum actually expands faster and more than steel, which is why first aluminum heads on cast/metal blocks had major head gasket issues, lol

So that should be a plus that the "nut" is aluminum and the bolt metal, they have different expansion rates when heated

This type of bolt remover can often work when others don't: https://i.pinimg.com/originals/af/f2/98/aff298c8b44d92f1c33cbe7aea3761dd.png

But they do require room around the bolt head

 

[markinms]

Thanks, it's worth a try. I'll start searching for one.

Mark

 

[Dirtman]

Don't forget good ole penetrating oil. Let that bastard soak overnight, then heat it. And as Eric pointed out, you have to curse at it.

 

[markinms]

Believe me, the "mild" cursing has already begun. Got so loud my wife came running out to the garage to see if I was alright.

I'll get some more penetrating oil on the bolt and see what I can do tomorrow.

Mark

 

[adabiri2]

Cut the head off another bolt and weld it to the bolt(allen head works good sometimes.)

Or, buy a pencil engraver(mine is Chicago brand), it is essentially a miniature chizzel/air hammer combination.

 

[rusty ol ranger]

I dont know if itll work once its *that* round.....but ive had luck hammering a smaller size socket on

 

[markinms]

Should be getting a bolt/stud remover I ordered on Amazon today. Welding a bolt head to the stud is not an option; space is too confined and hard to get at. I'll take a look at the pencil engraver idea next time I'm in town. I may try the smaller socket idea if the bolt/stud remover I'm getting fails to do its job.

Thanks for the feedback. I'll let ya'll know how it goes.

Mark

 

[MikeG]

There is a vice-grip version that is made just for this situation. The profile on the inside of the jaws is basically a triangle.... will have to dig mine out and get a pic.

If you truly could not get it out with a GOOD set of vice-grips, then that bolt is well and truly stuck. Find a set with good sharp serrations on the jaws, not old ones that have been used/abused on the welding table for years, or cheap pacific rim crap. Crank it down as tight as you can, then release the jaws, give the adjustment a teeny bit more, clamp, repeat, repeat, repeat. The teeth will start to dig into the bolt head, or what's left of it.

Tap on the handle of the vice-grips with a hammer in the direction you want it to go. A little impact sometimes helps. Good luck.

 

[Eddo Rogue]

If its steel, weld a nut onto the head, ideally slightly bigger.....just tack around the inside, wont take much. .023" or .030" wire ideally.

 

[MikeG]

Get one of these, if you don't need it now, you'll need it some day. This one is on a full-sized sheet of paper, so it might be too large for some bolts. Don't know if there is a smaller version. Might not work for you but someone else reading the thread could benefit someday.....