Stripped allen bolt head (not threads)

[j911brick]

Originally Posted by RWebb

some energetic person should summarize the several threads on this issue, and list the techniques in order of what to try first, etc. etc. down to last resort

Its not exactly that easy. The technique one uses will depend on the what and where the bolt is.

[RWebb]

well, edm is a definite last resort

[maui44]

You might want to try, Alden Industrial Series High-Speed Steel 3-Piece Pro Grabit Kit from Home Depot?

Industrial Series High-Speed Steel 3-Piece Pro Grabit Kit-8430P at The Home Depot

[KTL]

Just to add to the suggested methods, i've had good luck with welding a "new" bolt to the funked one. I had a countersunk/flat head screw with allen-head wrenching (inhex) as a drain plug on a fancy 3.0L 911 Autospeed oil sump plate that was stripped and overtightened. So I welded the threaded end of a regular hex head screw to the stripped countersunk head. Worked like a charm and no drilling/cutting required.

Point being is that you can get fairly clear access to the shift housing and weld a new bolt on there pretty easy. If you don't have a welder, sorry. Sure you need to protect the interior from weld sparks. But you sorta need to do that if you're drilling.

If the head is not stripped out too bad and has enough meat to support an easy-out, I think the fluted extractor is the way to go. If you can't find one that fits the stripped hole tightly, make it fit. Meaning, you grind the head of the extractor on your bench grinder until it is a tight fit in the stripped head. You should have to tap/press it into the stripped hole a bit. It'll get a good bite and pull that screw out easily.

[1990C4S]

Welding the head also loosens the bolt as the current heats the threads. I have a 'porta-spot' that I use on small trim screws. Even really old Phillips head exterior trim screws usually come out by hand.

[Omegablueray]

I did the same thing on the small allen bolts that hold down the shifter assembly. Use a bolt extractor. You just drill out the head of the bolts then hammer the bolt extractor and turn. Works great. check youtube for videos.

[Mitch Leland]

If the problem is beyond just a torqued thread that's really tight you can take a hammer and rap the head of the bolt to upset the treads if there's corrosion, rust or Lock-tite. Has anyone suggested heat around the body to expand the part?

[Maxhouse97]

I wouldn't heat due to the proximity of the rubber bushing. Impact wrench and back-out worked like a charm.

Replacement bolt is M8 x 20 metric.