Igordiver

I wanted to take out the Oil separator today since its gasket needs replacing. I just can't get it out without taking out the regulator housing. Needless to say I guess, but the 4 allen bolts from this housing are worn. (yep, round holes)
Any tips on how to remove them?
Thanx!!

Alan

Screw extractor?

Alan

Bilal928S4

Sometimes tapping in a bigger Allen key will get them out. I have sometimes cut slots in the head and used a screw driver, but in your location that is not possible due to space restrictions.

STRIKEMASTER

Something to try might be tapping a slightly larger 'Torx' driver into the head. Also put a piece of 'dry ice' on the head of the bolt to contract it and help break it free, BUT DON'T touch it till it warms back up. At -85F steel will snap like glass. Ask me how I know.

Chalkboss

You can also try a spiral screw extractor... uses a left-hand bit to drill a pilot then a spiral bit to unscrew. I have an Irwin set and have easily removed several with it. Well worth the dough I paid for the set.

Igordiver

I'll be going for the torx option today…

-Torx:check
-Hammer:check
-Beer:Check
-Cursig vocabulary:check

Good to go

Alan

Ummm - well I'm not not sure about that at all.... if they are totally rounded I wouldn't even bother with that path...

If (when?) that doesn't work - get the screw extractors.

Alan

WallyP

There are sets of bolt extractors that are like a socket with left-handed internal threads. Sears has them, among others. Don't know whether they have one to fit the outside of the Allen bolts.

Igordiver

Torx did the trick. One out. 3 broke. Screw extractors can recue it hopefully.
Makes sense that they break since they are nothing but rust.

Bilal928S4

Were you able to get the regulator housing out? If so, put a lot of penetrating fluid down the threads and let it work. Wally's brew works great.
Do it as many times as possible before trying the extractors. By the looks of the bolt that came out the others are rusted pretty good. You don't want to break an extractor in there.
Good luck and keep us posted with pictures.

WallyP

If you have access to the bolt ends, Bilal has some good suggestions. Repeated application of penetrant (50/50 acetone/Dexron), repeated rapping on the end with a center-punch, patience, and slotting the end of the bolt for screwdriver removal would be my first approach.

Igordiver

They're sunken in a bit so to speak.

Igordiver

I'm planning on attacking the bolts again on saturday. In the meantime I'll keep 'em soaked with the brew
I'd hoped that the housing would come off but somehow even the broken bolts don't let go of it yet.

WallyP

Probably rust build-up in the holes.

Mrmerlin

if these screws are broken off into the block and your planning on using heat to free them ,
it would be wise to drain the block first ,
the coolant will keep the block from heating up.

FWIW the best way to remove these bolts now is to drain the block,
then weld a nut onto the remaining bolt,
then unscrew the nut,
this will remove the broken part.