Stripped Flywheel Bolt

[billd]

Does anyone have any particularly useful tricks for removing a stripped flywheel bolt. I cut a slot in the bolt but have found that all of my usual tools for putting in the slot (which work fine on a 30ft-lb bolt) can't budge this 100+ ft-lb bolt.

I'm considering welding a 15mm nut to the bolt next.

[ChrisBennet]

When faced with removing bolts in a bolt circle like a flywheel, loosen the all a little first. If you remove them completely the last bolt will be much harder to remove as the flywheel will be "prying" against it.
In your case, I would install a couple of the flywheel bolts to relieve the pressure on the "stuck" one and see if that helps.
-Chris

[john walker's workshop]

to make it easier to deal with, a real hard wack from a heavy mallet directly down onto the bolt head tends to make them a lot easier to get moving.

[911pcars]

Assuming the PO or repair shop didn't use red Loctite on the threads and after trying all the above techniques, you can also drill the bolt head(s) off using a 1/2" drill motor and large drill bit. Once the tension is removed from the fastener, it should be easier to remove.

Good luck,
Sherwood

[iangray100]

You could also try a little heat applied to the bolt.

[cstreit]

I would try heat on it... Get it good and hot, dull red if you can, yo want to melt any loctite that may be on there. Then use an impact screwdriver to jerk it free. This has worked for me a few times.

[LeeH]

I had one flywheel bolt give me similar trouble. Since the bit was messed up anyway a friend just welded it to the bolt. Maybe it was the heat from the welds, but it came out with amazingly little torque.

[jbell959]

Go to sears and buy a Bolt Out set. One of them fits perfectly on the flywheel bolt with a slight tap of a hammer. Then get a socket and a breaker bar and it will come right out. Simple and Easy. Here is a link to the tool.

http://www.sears.com/sr/javasr/product.do?cat=Hand+Tools%2C+General+Purpose&pid=00952061000&vertical=TOOL&subcat=Bolt-Out%2C+Taps+%26+Dies&BV_UseBVCookie=Yes

I use it on every one I remove since they go in the trash anyway. It makes the job quick and painless and I've never had one slip.

[billd]

The bolt-out looks like a useful tool. However, I doubt it will work on this six-bolt flywheel since there is very little clearance between the bolt and the pilot bearing. I suspect it would work fine on a later 9-bolt flywheel.

[al lkosmal]

Heat is your friend. I tried removing the flywheel bolts from a 71T motor for days with no success. i was ready to bite people. Butane torch and a few minutes each and they came off easily.

[9elf]

Here's my solution. Notice the bolt welded to the end.

[Don Settergren]

Try an impact wrench. The hammering pulses sometimes breaks a bolt free that would otherwise bend a good breaker bar.

[Green 912]

Weld a cheap import missfit leftover from the bottom of the tool box 1/2 drive socket to it. No nead to make a removal tool just use a breaker bar or a impact gun on the socket. Toss the whole thing when out.

[billd]

I finally got the stuck bolts out. It wasn't easy. The things tried were:

1. Cut a slot in the bolt and attempt to turn the bolt with a pry-bar in the slot. I could not get enough torque before the head woudl bend and the pry-bar would slip out.

2. Weld a 17mm nut to the bolt. I did this but the weld - which was all the way through the outer part of the bolt head broke before I applied enough torque to turn the bolt.

3. Try to drill out the bolt. I drilled a nice 1/4" hole in the bolt (the center is apparently soft) but when I tried to enlarge it, I just dulled my bits on the hardened metal.

4. Grind off the bolt heads with an angle grinder. This worked, and once the tension was relieved, the bolts came out easily with an easy-out in the 1/4 holes drilled in step 3.

What a pain.

A photo of the removed bolts along with two unmolested ones for comparison.

[911pcars]

Congratulations. These are the jobs that separate man from mere mechanics. Did I get that right

Sherwood

[cstreit]

Originally posted by 9elf
Here's my solution. Notice the bolt welded to the end.

You sir are the poster child for overkill.