Another tricky screw removal

[RaceDiagnostics]

This time the machine screw is down a recessed aluminium hole and access from above is obscured on two sides, the screw head is about 5mm across.

Any suggestions on how to get it out? You can see someone has tried and failed.

It right on top of the fuel distributor on top of the engine.

 

[ajlelectronics]

Impact screwdriver with a decent bit.

 

[Ruffian]

Lots of penetrating fluid and some heat to try and get the corrosion to brake.

 

[addjunkie]

Impact screwdriver with a decent bit.

Long decent bit, so you get a clear hit

 

[RaceDiagnostics]

I was thinking about an impact driver but mine only has large (thick) sized bits, can you get ones that take normal diameter bits?

 

[brightspark]

grind it down in diameter till it fits it will help greatly if you can heat the ally up as it will expand more than the steel screw

 

[RaceDiagnostics]

Just worked out that my impact driver end pulls of to reveal a normal 1/2 inch type socket driver so I can use adapter to take it down to normal size bits. I will still need to find some long bits but expect I'll get them in screw fix.

 

[RaceDiagnostics]

Here we go, I'll grind down this bit and see if I can get access with this shaft to fit tomorrow, if not I'll use another adapter to go another size down. I also try a pre heat with a hot air gun, don't want to use a torch on the fuel distributer.

 

[Pete.]

I'd make a drill bushing that was a snug fit over that ally boss and put a drill down through it.

 

[RaceDiagnostics]

I'd make a drill bushing that was a snug fit over that ally boss and put a drill down through it.

Don't want metal chippings going into the engine intake if I can avoid it, if it comes to that I'll have to take the unit off the engine first.

 

[The_Yellow_Ardvark]

Get a decent fitting impact bit.

Warm the out casing and at same time pipe freezer spray onto screw.

Then add vinegar to the recess.

Repeat 3 or 4 times.

Them using an impact driver with gentle blows tighten the screw, then loosen.

 

[Pete.]

Don't want metal chippings going into the engine intake if I can avoid it, if it comes to that I'll have to take the unit off the engine first.

Tape up the intake then. You ought to do that no matter what method you use, because there's always a changce of getting a chip fly off the impact driver etc.

 

[Bladevane]

How about drilling a hole and using an Easyout extractor?

 

[The_Yellow_Ardvark]

How about drilling a hole and using an Easyout extractor?

That is an evil idea.

 

[Brad93]

Have you got a tig welder?

Blob weld on top, cool,blob weld on, cool until you get proud of the aluminium. Then put a M6/M8 nut over your blobs and weld that on. Turn said nut anti-clockwise and ta-dah

 

[Gareth J]

Done similar to the above with a mig. On similar size bolts in similar situations. Never on a fuel pump though, that might add to the things to think about.

 

[Dieselman 63]

How about drilling a hole and using an Easyout extractor?

You’ve obviously never snapped an easyout in a seized bolt

 

[bricol]

I reckon the inventor of those things must have a royalty agreement with all the spark eroding machine manufacturers . . . ;-)

 

[130]

If their is enough alloy around it heating will tighten the hole

 

[Seadog]

If their is enough alloy around it heating will tighten the hole