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Question

My 2002 1.9L A4 TDI spun a timing belt while in service. In the process of changing tb out, used a T-55 Torx on the head bolts. All head bolts except 2 cooperated. The 2 stuborn ones sufferred ridge failure, cracking, and stripping out on me. I now realize the bolts have a 12 point, triple square bit system. I tried a huge easy out that fit nicely into the now semi-round inner diameter of the head bolt, but, couldn't get a clean bite on the extra hard steel that the head bolts are made with. Also tried drilling them out with titanium bit, but same thing, the head bolts are very hard and I got nowhere fast. Any suggestions?

Submitted: 76 days and 10 hours ago.
Category: Car
Value: $14
Status: CLOSED
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Optional Information

Year: 2002
Make: Volkswagen
Make (other): Jetta
Model: TDI
Engine: A4, 1.9L TDI

Already Tried:
Tried the easy outs (IRWIN-HANSON EX-6 & EX-7 spiral screw extractors from local hardware store), could not get a clean bit. The EX-6 was too small, the EX-7 about correct fit, but, still gave way when torqued. Tried to drill out one of the bolt heads with a 1/2" Bosch Titanium drill bit,but, bolts are too hard.

Posted by danny 76 days and 10 hours ago.

Answer

Heat those bad boy's up, and grab them with some channel locks. See how that works.

 

Thanks Dan

76 days and 10 hours ago.

Reply

Heating sounds like a good idea, but, access to the head bolt is limited because they are recessed in pockets that won't allow for grasping and turning with channel locks.

Posted by danny 76 days and 10 hours ago.

Answer

Can you tap what little hole is there and put a bolt in it with thread lock. OR a spot weld. Then use the bolt to turn it out. Thanks Dan

76 days and 9 hours ago.

Reply

Don't know if I can tap or not? I will try it. The welding sounds good, but, not sure if I can get the MIG tip down in there or not. Also, do you think welding may cause electrical component problems, for example the car's computer to be damaged?

Accepted Answer

Well you are supposed to unhook the battery but it could revert from ground. There are alot of speculation about that. And you could unhook you ecm. I have welded on several cars and no problem. You got me thinking about liability now. lol. But I think you will be alright. If you want get a self tapping bolt and get it started in there and put a couple of layers of jb weld on it.

 

Thanks Dan

 

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Expert: danny
Pos. Feedback: 98.0 %
Accepts: 
Answered: 9/7/2009

Mechanic

Mechanic at school corp bus garage! Experience in fleet diesel and regular automotive.

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