CV Axle removal nightmare

[bsodt]

I decided to replace my clutch on the 2000 Boxster 2.7 with 131,000 miles last weekend. So far nothing bad till I tried to remove the 6 bolts that hold the CV axle to the transmission. I tried to find a 6mm allen head wrench that fit tight but none were an exact fit. Anyways I got 5 off one side and the last one stripped. So far 2 have stripped on the other side. I am at a loss on how to get the transmission out now without removing both axles at the same time I pull the tranny out. They seem to be on there way tight also as I am having to use a breaker bar just to loosen.

Anyone ran into this and have a great idea on how to get the stripped bolts out before I try to remove the tranny to replace the clutch????

Any help is more than appreciated.

Bill

[Rod Schneider]

Unfortunately, you've probably stripped out the heads by using the wrong tool. Those bolts are usually 12 point triplesquare and require the proper tool, which is available from our host. As you've discovered, 6 point Allen wrenches almost fit, but are not quite right. You have a couple of choices for getting the ruined bolts out. You may be able to grab the heads with a good pair of Vice Grip pliers and get them to come loose, but more likely, you'll need to grind down or cut off the heads to get the axles off, and then unscrew the shanks.
Even with the proper tool, make sure that the recess in the bolt head is cleaned out and the tool is fully seated. These bolts are torqued to either 60 or 80 foot pounds, depending on the bolt size.

[bsodt]

I called pelican parts to get the part and they said its part # PEL-CV-T1. However my bolts do not appear to be 12 point bolts. Is this the part you had mentioned above?


Thanks for your help!!!

[Rod Schneider]

That's the tool. It is possible that your bolts were replaced with 6 point bolts, take a good look at one you haven't tried to remove yet. Make sure the head is cleaned out completely.

[bsodt]

Looking at it closer it appears I have some 12 point and some allen head. I guess previous owner replaced some..... Dang, lessons learned.

[mreid]

Get a 3/8 drive bit in the correct size. Put it on an extension and drive it into full engagement with a few light taps from a BFH, then use the ratchet to remove the bolt. An Allen wrench won't usually strip the tips out of a 12 point and by knocking it all the way in, you clean the socket head and ensure full engagement. Good luck!

[turboflyer]

Probably have to drill the head off. Then remove the threaded portion. You might get lucky with an easy out type remover or small stud remover. Good luck.

[bala]

Drilling the bolt would be my last choice. Cut the bolt head on two sides to make it rectangular - sort of. Use lots of PB blaster and soak it. I heated mine with a blow torch - short targeted flame and sprayed PB blaster. When you are satisfied it is ready use a wrench to twist slowly. Don't fight it. Worst case you can drill it and if that don't work cut the head, remove the joint and then you will have a long piece to grab on to. HF sells a socket kit that bites into the bolts when you turn them counter clockwise. Though I have never used on this bolt it has worked well for me in other situations. Good luck.

[bell]

You may be able to hammer on a normal 12 point socket over the head of the axle bolt, but the cv boot may interfere.....
You can also try hammering in a triple square which is the next size up.....
I have also gotten lucky using a pair of Good vice grips, and the hammered in triple square. ....
Once it breaks lose it'll just spin out, so before you cut the head try a chisel to break it loose. .