So I decided to take on the 'simple' job of replacing the valve cover gaskets since I have a small leak from both covers. All the bolts came out easily except one, where I guess I was a litle hastly in seating the Snap-on 5mm allen socket, and I rounded it out

Luckily it's one of the more accessible ones. What's the best option for shifting it now (assuming someone has run into this before)? I though about cutting a slot across the head of the bolt and using an impact driver with a flat screwdriver bit.

All suggestions glady accepted

 

Depends on your access to it. The one that I rounded out was best attacked with a nice sharp cold chisel and hammer. Only took a few whacks.

Chris.

 

vice grips might work well also.

 

Your method should work.

Measure the shank of one of the good bolts and use a drill bit a few thou smaller. Drill the head of the rounded socket head cap screw and snap it off.

 

Cold chisel worked with mine. I tried cutting a slot in the bolt head with my Dremel tool and using a screwdriver first, but that didn't prove effective.

These bolts are pretty soft, and stripping the hex socket is quite common.

 

as others already suggested, get it moving with a small chisel or vice grips if you can. Once they are cracked loose, they usually come out easy

Drill the head off as a last resort. Once the VC is off you can grab the nubbin that is left with pliers

those little buggers are soft... Someone should spend copious amounts of time re-engineering this $1 part

 

Thanks guys - I'll give it a go with the cold chisel tomorrow, and go from there.

 

I've taken out a couple with a torx bit tapped in. The blades of the torx bite into the side of the allen head and are easily removed.

 

never had to do this on a VC bolt but really good suggestion

had to do something like this on the muffler bracket bolts before... Nasty things

 

Well it's out - I tried one of those fluted bolt extractors first, and because the bolt is so soft, all it did was cut a nice bevel on the head. The winner was the hammer and cold chisel - 5 or 6 sharp taps and it was free. Thanks all!

 

sweet!

great news, congrats

 

So dumb question... I am assuming that with the chisel you are tapping the head of the bolt off. Do you then drill out the shaft after removing the valve cover?

I had trouble with the top rear bolt on the driver's side lower VC, but stopped before rounding out the head. Just trying to figure out the best approach for removal.

 

you are using the chisel to rotate the bolt via the perimeter of the head.
Once there is some rotation they almost always come out easy.

another tip is to tap each bolt with the allen inserted prior to attempting to remove it. This is before there is trouble, of course.
hopefully all of that makes sense

 

yes exactly - just position the chisel on the edge of the head and hit it so it has the effect of turning the bolt. Once you break it free it spins by hand easily. Seems the secret is to break the bond on these first - so for the other side I will set the 5mm allen socket first and give a good tap with a hammer to help that process before applying pressure.

 

exactly!

a little sharp rap helps free the head up