Ack! Stripped allen head bolt!
 

Started out intending to replace the shifter bushings....

Got down to the 5 allen head bolts that hold the shifter on and...

The pair of 5mm allen heads that were closed to the emergency break were both pretty rouded off on the inside.

I've tried using an extract and a drill bit on one of them with a 10volt cordless drill, and the only thing I've done is shave out the inside of the head.

I have an appointment to get them removed and replaced with good bolts on thursday. Anybody have any advice in the meantime to avoid having to pay 1-2 hours labor on this?

Thanks,

Garrett

Need a drastic solution? Go buy a "star drive" socket that's a little bigger than the allen head opening. Get a hammer and pound it into the opening. Get big on it. Once it has been seated, simply put your ratchet handle on it and turn the bolt out. You'll probabaly destroy the socket in the process, but you'll most likely get the bolt out. Good luck.

My solution was to grind away one side wall on the bolt with my dremel and leave an edge for me to place a tap. I then proceeded to gently tap on the head of the tap in the direction the bolts needed to turn. Some required more gentleness than others, but they all gave in in the end.

Cut a slot in it with a dremmel. Insert a big screwdriver into slot to remove.

I know this is a more "brutal" solution, but I'd use a hamer and chisle.

Slot it then...

Get one of those "Screwdrivers" that turn when you hit the top of it...

I'm with Ed and Chris, slot it - big screw driver. May have to use a pipe wrench or shifter to assist with leverage on the screw driver.

"Slot it then... Get one of those "Screwdrivers" that turn when you hit the top of it..."

I'm with Chris. That would be an impact driver, less than $10 from the cheap tool store. Don't forget the large hammer.

A hammer and chisel are pretty crude and sometime indescriminant, especially around the aluminum shift housing.

Sherwood