Removing stripped aluminum bolt
#1
Junior Member
Thread Starter
Removing stripped aluminum bolt
Does anyone have any advice on how to remove this stripped aluminum bolt?
I can't find a socket that will fit, an E8 torx is the correct socket for this bolt but that is too big now. Have tried various smaller torx and hex sockets, nothing fits once torque is applied to the wrench, the socket easily slips off.
It's fastening the ignition coil for cylinder #8 on my M157, right at the very back close to the firewall, so I can't really 'push' against the socket to get any purchase.
I don't care about damaging the bolt or coil, they'll be replaced.
Thanks
I can't find a socket that will fit, an E8 torx is the correct socket for this bolt but that is too big now. Have tried various smaller torx and hex sockets, nothing fits once torque is applied to the wrench, the socket easily slips off.
It's fastening the ignition coil for cylinder #8 on my M157, right at the very back close to the firewall, so I can't really 'push' against the socket to get any purchase.
I don't care about damaging the bolt or coil, they'll be replaced.
Thanks
#3
MBWorld Fanatic!
Time to buy a new tool !!!! yeah you.
3/8 in. Drive SAE Bolt Extractor Socket Set, 9-Piece (harborfreight.com)
3/8 in. Drive Metric Bolt Extractor Socket Set, 9-Piece (harborfreight.com)
Multi-Spline Screw Extractor Set, 25-Piece (harborfreight.com)
3/8 in. Drive SAE Bolt Extractor Socket Set, 9-Piece (harborfreight.com)
3/8 in. Drive Metric Bolt Extractor Socket Set, 9-Piece (harborfreight.com)
Multi-Spline Screw Extractor Set, 25-Piece (harborfreight.com)
Gator Grip King Socket The Original Professional Grade Self-Adjusting Universal Socket with over 450FT Pounds of Power. Self-Adjusts for shape and size as well as Standard and Metric Application - Amazon.com
THINKPRO Upgraded Bolt Extractor Set, 15 PCS Impact Bolt & Nut Remover Set, Stripped Lug Nut Remover, Extraction Socket Set for Removing Damaged, Frozen, Rusted, Rounded-Off Bolts, Nuts & Screws - Amazon.com
#4
MBWorld Fanatic!
The bolt extractor is your best bet. They're designed to bite/grip increasingly with increasing ccw torque. Pliers or visegrips can sometimes work, but usually damage the bolt and lessen the efficacy of a bolt extractor.
#6
Member
Yup, bolt extractor looks like the only way to go here as too much metal is missing. The sharp teeth will dig in, create their own connection and give you a good grip. Might be a good idea to review the tool that did this to determine if it is worn out and should be discarded (or at least put in a dark space in the tool box for those "special" uses where you don't care about whether it survives).
Just an afterthought, have you considered using those sacrificial pigtails on your coils' wiring harnesses that help stop oil wicking into your ignition wiring harness and destroying other $tuff? A cheap method of protection in case there's an oil leak or seepage.
Just an afterthought, have you considered using those sacrificial pigtails on your coils' wiring harnesses that help stop oil wicking into your ignition wiring harness and destroying other $tuff? A cheap method of protection in case there's an oil leak or seepage.
#7
Junior Member
Thread Starter
Yup, bolt extractor looks like the only way to go here as too much metal is missing. The sharp teeth will dig in, create their own connection and give you a good grip. Might be a good idea to review the tool that did this to determine if it is worn out and should be discarded (or at least put in a dark space in the tool box for those "special" uses where you don't care about whether it survives).
Just an afterthought, have you considered using those sacrificial pigtails on your coils' wiring harnesses that help stop oil wicking into your ignition wiring harness and destroying other $tuff? A cheap method of protection in case there's an oil leak or seepage.
Just an afterthought, have you considered using those sacrificial pigtails on your coils' wiring harnesses that help stop oil wicking into your ignition wiring harness and destroying other $tuff? A cheap method of protection in case there's an oil leak or seepage.
So, about the bolt extractors, the set I bought only went as low as 8mm, that's too big for an E8 bolt. Think a 6mm bolt extractor will work. Will report back.
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#8
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2015 SL400 (M276 Turbo), 2014 C350 Sport (M276 NA), 2004 SL500 (M113), 2004 Audi TT225 (BEA)
These are remarkable pliers. Search Amazon for Vampliers. They make different styles and are made in Japan (not China). (At least mine are.)
VAMPLIERS 7" Screw Extractor Pliers for the DIY Guy. Carbon Steel Stripped Screw Remover Tool. Secially Designed for Extracting Stripped/Rusted/Damaged Screw & Fasteners. - Amazon.com
Last edited by JettaRed; 06-22-2024 at 09:33 AM.
The following users liked this post:
jcarsnz (07-06-2024)
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JettaRed (06-22-2024)
#10
Junior Member
Thread Starter
Ignition coil bolt is still firmly attached.
Tried a 6mm bolt extractor.. this did a great job at rounding off what remained of the edges.
Then tried jb welding a socket to the bolt, unfortunately the jb weld was fantastic at bonding to the socket but only barely bonded to the head and base of the bolt. I tried a second socket, but with additional jb weld applied, with the same result (I waited over 24 hrs to allow the jb weld to cure etc).
@JettaRed those pliers look interesting, might order those now, thanks.
Otherwise I'm planning to let my mechanic take a look when the ML is due an oil change later in the year. There is no rush as I was only completing this job (new plugs/coils) as preventative maintenance.
Tried a 6mm bolt extractor.. this did a great job at rounding off what remained of the edges.
Then tried jb welding a socket to the bolt, unfortunately the jb weld was fantastic at bonding to the socket but only barely bonded to the head and base of the bolt. I tried a second socket, but with additional jb weld applied, with the same result (I waited over 24 hrs to allow the jb weld to cure etc).
@JettaRed those pliers look interesting, might order those now, thanks.
Otherwise I'm planning to let my mechanic take a look when the ML is due an oil change later in the year. There is no rush as I was only completing this job (new plugs/coils) as preventative maintenance.
#11
Does anyone have any advice on how to remove this stripped aluminum bolt?
I can't find a socket that will fit, an E8 torx is the correct socket for this bolt but that is too big now. Have tried various smaller torx and hex sockets, nothing fits once torque is applied to the wrench, the socket easily slips off.
It's fastening the ignition coil for cylinder #8 on my M157, right at the very back close to the firewall, so I can't really 'push' against the socket to get any purchase.
I don't care about damaging the bolt or coil, they'll be replaced.
Thanks
I can't find a socket that will fit, an E8 torx is the correct socket for this bolt but that is too big now. Have tried various smaller torx and hex sockets, nothing fits once torque is applied to the wrench, the socket easily slips off.
It's fastening the ignition coil for cylinder #8 on my M157, right at the very back close to the firewall, so I can't really 'push' against the socket to get any purchase.
I don't care about damaging the bolt or coil, they'll be replaced.
Thanks
The following users liked this post:
jcarsnz (07-08-2024)
#12
MBWorld Fanatic!
The bolt's fluted cap likely compromised the efficacy of the 6mm extractor's grip. With the flutes gone, a smaller size extractor might do the job. Harbor Freight has a set of bolt/stud extractors (its Icon brand) for $60, but letting your mechanic deal with it might be your best alternative, as it might require drilling and a stud extractor. I often wonder how the design engineers choose fasteners for each application. I changed the oil in my BMW yesterday. The drain plug is an 8mm hex key and the filter cannister drain plug is a T55 -- no reason both could not be one or the other.
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jcarsnz (07-08-2024)
#13
Junior Member
Thread Starter
Purchased these screw extractor pliers (the smallest available), still no use, there isn't enough space around cylinder 8 to get a good angle to apply some elbow grease with the pliers.
So ended up waving the white flag and got my mechanic to take a look... $50 USD later and it's out:
How they did it I don't know, lady at reception only knew "the guys had to remove the air box to get access"... lol. whatever, it's out now and I have the new plug and coil installed. job done!
So ended up waving the white flag and got my mechanic to take a look... $50 USD later and it's out:
How they did it I don't know, lady at reception only knew "the guys had to remove the air box to get access"... lol. whatever, it's out now and I have the new plug and coil installed. job done!