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Thread: stuck screw extraction nightmare

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    Default stuck screw extraction nightmare



    I set out today to install some Quadratec mirrors (https://www.quadratec.com/products/13111_0410_14.htm) so I could have some side mirrors while rolling without doors.

    The mirror brackets installation requires removal of 4 T-40 screws from the Jeep (which obviously have never been removed since manufacture in ~2005). Three of these were relatively easily removed, but the fourth stripped beyond utility. I've spent the afternoon trying to extract this screw quite unsuccessfully. The screw head is counter-sunk, and I am unable to cut a slot into it that is deep enough to be useful. I tried two types of extraction bits while attempting to drill out the screw shaft, and neither worked. I've given up for today as the second extractor bit broke off in the hole I drilled out of the shaft of the screw. Now that I have a hardened extractor bit in the center of my screw / hole, I do not have any idea how to safely remove this mess.

    I need to get this screw out somehow. I no longer have any viable plan for how to get it out. Any ideas?

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    Default Re: stuck screw extraction nightmare



    Is there a chance you can get to it from behind the door panel? Maybe get a vise grip on it and twist it out that way?

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    Default Re: stuck screw extraction nightmare



    Any pics?

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    Default Re: stuck screw extraction nightmare



    I had a similar problem here http://www.frontrange4x4.com/forums/...ch-Sound/page4

    a dremel with carbide bits did it for me. I have a dremel 200 you can borrow.

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    Default Re: stuck screw extraction nightmare



    I guess I'll go take a picture. It's hideous and embarrassing now. =\

    Edit, here it is

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    Default Re: stuck screw extraction nightmare



    I used a Dremel with a carbide burr to gouge a broken extractor from a cylinder head. It was slow, tedious work, but resulted in a hole that could be cleaned up with no additional work.

    Depending on how much material is left in the hole, it may be feasible to weld another fastener to the stuck one, and turn both out.

    In any case, utilize eye protection!
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    Default Re: stuck screw extraction nightmare



    I did the same danged thing about 5 days ago. The pulley attachment bolt for the york A/C compressor. Into the end of the compressor's crankshaft (a piece I didn't wish to trash).

    I'll +1 what others have said - dremel. High speed, little pressure. Thin bit. I used two or three bits and it took an hour. I used the bits that came in the dremel multi-bit box - I don't know if they were special or not - they were the size and I was getting moving (stores closed - late night garage grunge project). Patience and you'll get there. PITA none the less.

    +1 on Mike's eye protection as you will likely fully consume a dremel bit or two and at the end pieces will likely fly.

    The resultant hole was the "next size up" in extractor size which was successful - though with caution.

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    Default Re: stuck screw extraction nightmare



    Hypoid previously posted:
    "Depending on how much material is left in the hole, it may be feasible to weld another fastener to the stuck one, and turn both out."

    That may be an option. I do not have the tools, skill, or experience to attempt this, though.

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    Default Re: stuck screw extraction nightmare



    Thx for the pic.

    You might try using a chisel, on an angle, to try and bite into the head to try to turn the bolt out of the fastener. Worst case is you'll munge the remaining head.

    Or a 1" or 1.5" dremel cutting wheel to try to cut a more hefty slot into the head to try a slotted (standard) screw driver to try to turn the bolt out.

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    Default Re: stuck screw extraction nightmare



    Jim previously posted:
    "You might try using a chisel, on an angle, to try and bite into the head to try to turn the bolt out of the fastener. Worst case is you'll munge the remaining head."

    On an angle meaning try to turn the screw by tapping the chisel? Or do you mean to just tap the chisel to set it into the screw head and then turn it by hand? Either way, I need to acquire a chisel to try this.

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    Default Re: stuck screw extraction nightmare



    Doink previously posted:
    "Is there a chance you can get to it from behind the door panel? Maybe get a vise grip on it and twist it out that way?"

    Good thought, and I have no idea if this is possible where the screw is located. It is adjacent to the upper hinge for the driver side door. Any idea how I might access this from inside the Jeep?

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    Default Re: stuck screw extraction nightmare



    Chisel on an angle for a CCW rotation of the bolt. Hammer whack onto chisel to induce the turn.

    Method 2 in this page:
    https://eztoolhub.com/6-tips-removin...bolt-or-screw/

    If the bolt doesn't turn, then yes, possibly use the chisel to create a slot for a slotted screwdriver to use. I'd think you'd not do a single chisel straight into the head as the outer edges of the chisel end might contact the body metal too soon. You might need to cut one half of the slot, using the chisel on an angle - somewhat mimicking the angle of the hole's taper.

    You could drive it to a welder to weld on a nut - but this is finish paint and you don't wish to munge the paint.

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    Default Re: stuck screw extraction nightmare



    open_circuit previously posted:
    "Good thought, and I have no idea if this is possible where the screw is located. It is adjacent to the upper hinge for the driver side door. Any idea how I might access this from inside the Jeep?"

    I've never removed the door panels before so I'm not 100% sure what's accessible behind them. I just thought since the mirrors screw into the doors, there might be a chance of removing the door panel and gaining access to the screw from behind.

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    Default Re: stuck screw extraction nightmare



    Doink previously posted:
    "I've never removed the door panels before so I'm not 100% sure what's accessible behind them."

    Hit his Quadratec link - it's the windshield pillar - moving from the door to the body.

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    Default Re: stuck screw extraction nightmare



    open_circuit previously posted:
    "That may be an option. I do not have the tools, skill, or experience to attempt this, though."

    If you wish to drive up here - I likely have much of the tools aside from a welder.

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    Default Re: stuck screw extraction nightmare



    Jim previously posted:
    "If you wish to drive up here - I likely have much of the tools aside from a welder."

    I'll think about it tomorrow and make a plan for later in the week. Won't have time until Tuesday to tackle this again. I do have a Dremel, just need to come up with some carbide bits to remove the broken extractor shaft. However, the chisel might work and would eliminate the need to deal with the broken bit.

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    Default Re: stuck screw extraction nightmare



    If you're looking for a chisel (and have a bit of time and wish to save some cost) - pawn shops might have a jumble box of tools (for a buck). Dremel bits should be easy to source.

    PM if you wish to stop up. I have a Dremel, chisels, hammer, air impact chisel.

    Another tip for a stuck fastener - impact. You could use a round chisel, into the core of the bolt with one hefty whack with a hammer. Goal is to try to break / upset the bond on the threads between the bolt and nut.

    If you can get behind the fastener (via a hole of one of the other removed bolts????) try to spray some stuck fastener penetrant.

    g'luck! (you'll get it done - Class is in session - Life 101 isn't always a fun class - but you will learn some good skills).

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    Default Re: stuck screw extraction nightmare



    Jeep has had an affinity for Torx head fasteners for many years. I've fought with them a lot in the past...

    Too late at this point but for future reference; I've found the best approach includes liberal use of penetrating oil several days before you pickup a wrench. If the surface is painted over, you may need to cut around the edge to allow the oil to pass though to the threads. After a good soaking, I use an impact driver (the shock of the hammer helps loosen stubborn threads).

    Given where things stand now, you may be able to drill our the extractor with a carbide bit. Or I think the best bet would be to take it to someone with a welder and have them weld a nut to the head (or whats left of it), then use a socket to break it loose. Using heat is also a good way to break loose a stuck fastener but you don't want to mess up your paint if you can avoid it.
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    Default Re: stuck screw extraction nightmare



    As a worst case scenario, you could drill 4 smaller holes around the head of the screw. Basically just to get the extractor out. Once it is out, drill out the rest of the head so you can remove the bracket. Then you can hopefully apply good penetrant and hopefully remove the rest of the screw by grabbing what remains with some vise grips.

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    Default Re: stuck screw extraction nightmare



    Something not tough any more, WAKE THE BOLT UP.....this is old school tricks here. when said bolt has not moved in years it is wise to WAKE it up, this is done with punch and mallet. One maybe to good strikes and it should let loose the paint, and what not for the factory install. Your not after deforming the bolt just get some shock init to loosen things up.

    I never believed in this. Tell I had an odd sized Trox head bolt in a Porsche Cam shaft, this is what the Factory maintenance book said to do....worked like a charm!
    ___________
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