Head bolt removal problems

[billsimer]

I'm having a difficult time loosening the head bolts on the engine from my 1997 Boxster. I've ruined 2 Snap-on Torx tools, and one Craftsman Torx tool in the process. The Craftsman tool loosened three head bolts then pretty much shattered. The Snap-on tools stripped the heads of two bolts and have "bent" the splines on the Torx tools. Any tips on how to remove the head bolts would really be appreciated.

[BYprodriver]

Originally Posted by billsimer

I'm having a difficult time loosening the head bolts on the engine from my 1997 Boxster. I've ruined 2 Snap-on Torx tools, and one Craftsman Torx tool in the process. The Craftsman tool loosened three head bolts then pretty much shattered. The Snap-on tools stripped the heads of two bolts and have "bent" the splines on the Torx tools. Any tips on how to remove the head bolts would really be appreciated.

This is normally a situation where I paste my standard recommendation to buy Snap-On torx socket bits, so assuming you have new 1/2" drive torx bit's the only thing I can recommend is getting the longest breaker bar that's practical for better leverage & less slippage. Are the bolts T50? If so they should be discarded for the updated T55 bolts & I guess you know better than I why.

[EBS_Don]

You can also drill the head of the bolt off and, of course, upgrade as Bill says. They make a nice loud popping noise when the head snaps off during the drilling process that sounds like a .22!

[txhokie4life]

Guess I've been lucky -- I usually use any old T50/T55 and pull out my 4' extension bar
and get a nice chest workout.

I do tap the sockets into place to make sure they've seated well.

Make sure you are applying pressure along an even plane and not Torque the Torx.
I usually put one hand pushing down the ratchet end and the other at the end of the bar.
and push only with my right while trying to keep the left from allowing the ratchet to move.

Now I'm sure I've jinxed myself and I'll be in your boat on my next teardown.

Mike

[billsimer]

Thanks for the suggestions for removal of the stubborn and stripped head bolts. As you noted I know why the bolts were upgraded to T55 and I'll gladly go that route when the heads go back on. I'm looking forward to the sound effects when drilling out the head bolts that my new Snap-On Torx sockets won't remove. Glad that Snap-On has a replacement guarantee!

Bill