Bolt Head Shirred on Water Pump-Help

[JRoser]

My Water Pump was leaking coolant on my 1998 Boxster, so I decided to replace the water pump gasket.

After removing all the components described in Wayne's Technical Article of Water Pump and Thermostat Replacement, I came across one unforgiving bolt on the Water Pump that would not budge. The 10mm flexhead would not grip the very top bolt. I noticed that the pulley for the water pump was almost touching the bolt. On further inspection I found that the pulley had actually shirred the bolt head and and rubbed off 3 of the points of the bolt head making it impossible to take off with the required 10mm flexhead.

So, I tried the following methods:
1. Liquid Wrench spray with a vise a needle nose vice grip. Result: Won't stay on and keeps slipping because of the angle.
2. Attaching another nut to the sheared bolt head with JB Weld, and trying to unscrew it. Result: JB Weld is not holding the nut.

Other Factors: If you were looking directly at the water pump and had you head even with the pulley, you would see the pulley wheel was covering part of the bolt head, meaning you couldn't get a socket around it. You have to come from the top because of the pulley wheel covering part of the bolt head. If you look at any manual like Bentley's or Wayne's article you would not see the pulley up partially over the bolt head.

Question 1: Can I just pull the pulley straight out someway?

Question 2: Can you provide me any other avenues to solve this problem?

Thanks

[Dale_K]

Sometimes a small pair of vicegrips can get a grip on mangled bolt heads. I've never done a Boxster water pump, so I don't know if there's enough room but they make some pretty small vice grips. The advantage of vice grips is you can tighten them down like a mofo because of the overcenter action and adjustment bolt. Then you can let go and the pliers hang on by themselves because they're so tight. Tap the grip end with a little hammer and hope for the best. Many years ago when I actually worked with tools for a living I used vice grips to remove the remnants of broken-off studs.

I think some vice grips are directional - the teeth are oriented like a pipe wrench. They only grip perfect going one way.

[JRoser]

Thanks, Dale_K. I have tried the needle nose vice grips. I'll look for something smaller in the vice grip area, and look into the directional way you mentioned.

[rickybbear]

maybe grind the bolt head off, remove the pump housing, than grab the shaft of the bolt? you need new bolts anyway,, good luck.

[very~worn~944]

Get a small pry bar or large screwdriver. You're replacing the pump anyways...the bushings is shot- the impeller and the pulley have worn out of position from the belt tension. Jam your screwdriver between the pulley and pump housing and flex the pulley out of the socket's way (provided the bolt isn't mangled from plyers and vice grips). There's slight play in the failed pump.

[JRoser]

Thanks for the help.

I ended up realizing the pump needed to be replaced, so I pried the pulley from housing and was able to get the open ended adjustable grip wrench in position. Because the bolt head would not accept a standard wrench.

THANKS!

[Zeke]

My eyes hurt.

I think that "shirred" my brain.