Exhaust Barrel Nut Stripped

Number1_dog · 09-03-2008, 07:27 AM

The barrel nut allen key will not go deep enough into the #3 exhaust port barrel nut to get a hold to turn it, the top part of the barrel nut seems to be rounded. I’m assuming that the prior owner used a longer stud and that it is protruding higher into the barrel nut than the correct stud would have and is preventing me from getting the tool deep engouh to get a firm hold to turn it and remove it.

I was thinking of drilling off the top of the stud so the tool can go deeper into the barrel nut, but where do I find a 9 inch drill bit that small?

any other ideas?

beamonk · 09-03-2008, 07:45 AM

If you can get an air hammer/ chisel up in there, use that. It will unscrew it right off. be sure to aim it in the direction lefty loosey.

Zeke · 09-03-2008, 07:51 AM

You can buy long drill bits, but that's gonna be a tough job to drill down the length of the stud and not damage the hex portion of the nut. Before doing that make sure all dirt and debris are out of the hex cavity and that your allen tool is sharp and square at the tip. Use the best quaity allen tool you can find. You have but one more shot at this. If you have a torch, that will be most helpful . I usually heat and soak with PB Blaster several times, then a final heat to cherry red. Heating and then squirting the PB on cool down seems to draw it in.

Fast Corners · 09-03-2008, 08:41 AM

+1 on Milt's recommendation. Use of the long extension allen socket tool is recommended. Using this on a ratchet will allow you to push the allen into the barrel nut while you are turning it. This will help you get a better bite on the barrel nut and lessen the tendency for the allen to back out of a damaged nut.

3.2 CAB · 09-03-2008, 08:48 AM

If an allen won't grip, you might want to give a Torx-bit a try. The "splines" will bite into the inner portion of the nut, and you might be able to get it loosened this way. Good luck!! Tony.

Rich Lambert · Rich Lambert's Garage

This happened to me. What worked, was to cut off the rounded tip of the allen wrench. That gave it enough bite to get the nut off. When I put it back together I stuck a couple of washers on there so I wouldn't have to modify the stud.

Zeke · 09-03-2008, 09:50 AM

Quote:

Originally Posted by Rich Lambert

This happened to me. What worked, was to cut off the rounded tip of the allen wrench. That gave it enough bite to get the nut off. When I put it back together I stuck a couple of washers on there so I wouldn't have to modify the stud.

That's what I said to do. Let me add, though, that the stud may have backed out and that is why it is intruding into the socket area (although I thought the nuts were designed to not do that). Anyway, I'd think about a new stud after all this is removed. Certainly all new exhaust nuts.

Rich Lambert · Rich Lambert's Garage

Quote:

Originally Posted by milt

That's what I said to do. Let me add, though, that the stud may have backed out and that is why it is intruding into the socket area (although I thought the nuts were designed to not do that). Anyway, I'd think about a new stud after all this is removed. Certainly all new exhaust nuts.

Great minds think alike...