Rounded off the Bolt on the Hydraulic Tensioner...

I posted this in the Technical Chat forum but I hope the mods don't mind if I cross post here, since I do have a Gen1.

So... My dumba$$ rounded off the bolt that holds the tensioner, by using a socket wrench. The worst part is, is that I had a set of 12 pt box end wrenches in my drawer that I should have used but didn't.

The only solution I can think of is welding the box end wrench to the bolt but:

1. I don't have a welder
2. I don't have any welding experience

Can anyone here give me some pointers on welding a nut or wrench on to the bolt or any other way of getting this bolt off.

I did manage to get the inner bolt out by using a swivel socket and extension.

I attached a pic of the rounded bolt.

 

Craftsman has special spiral grooved internal sockets, as well as Snap on, MAC and Matco tools, which will remove that damaged bolt

 

I almost did that a week ago... I was lucky, it came out but it was bad enough that I replaced it with a new bolt.

Try a 7/16 wrench. Hammer it on.

 

You want to use a 6 point, not a 12, so all the flats are engaged.

Sometimes you can file dress the edges a bit and use a smaller socket size, even if you tap into place. That could including using an SAE on that metric head.

Apply pentrant where the treads are exposed at the top. Breaking it loose is the key, once you get that, you'll be able to finish getting it out.

 

Wait was it a 12mm or 10mm? If 12 try hammering on a 7/16 wrench. If it's 10mm try a 3/8.


If that doesn't work try vise grips. If vise grips fail drill it out. Or cut the head off the bolt with a dremel or multi-tool/zip-saw. Then with the tensioner off you should be able to get the rest of bolt with vise grips.

 

Yes, I should be using a 6 point box end wrench. After I stripped the bolt with a socket, I fit my box end wrench to see if it fit better, and it does because the tensioner does not give much room to use a socket wrench.

I guess I'll have to add another set of box end wrenches, this time the 6 point.

 

It's a 12mm bolt but the only issue is that the tensioner gets in the way of getting a socket to fit flat/snugg. The box end wrench fits perfectly.

I tried the vise grips, but to no avail. I'll have to try the hammer method tomorrow morning...

 

Also... I unbolted my AC compressor, scooched it up... then unbolted and removed that AC bracket that is in the way.

Added 30 min and was a pain. But... I thought the AC bracket had to come out?

 

That bolt isn't too bad... Unless that was earlier today.... Got a 12mm deep socket?

Got a grinder? Belt sander? A file & a while? Grind down the wrenchs end thickness a lil bit

 

lowes and home depot and others sell what is referred to as a flank drive socket or wrench... they grab the flats of the fasteners and not the corners. I would really hate for you to spend $ on tools to make attempts... Harbour Freight is ALWAYS running sales, you might be able to pick up these

 

I may have to remove the a/c compressor if I go the drill route.

To get to the inner bolt of the tensioner, you can access that bolt from under the car by using a swivel socket and an extenstion.

 

6 point 12mm deep socket helped me alot.

If it still looks that good don't gnarl it up. Get a 12 mm Deep

 

I just looked this up on HF's website and this is the first review:

"worked
just bought it today for a rounded off oil pan drain bolt i had been working at it some time yesterday with failure. decided to try this tool it worked perfect my next step was to weld a saccket to the bolt which i would have done but zero weld experiance thought I try this.very happy now can enjoy christmas eve"


Definitely going to have to try this first thing tomorrow morning!

 

You don't have a small extension? Should help the wrench clearance same as a deep socket?

 

I think you can get it still with a deep socket or a short extension. If you can get a 12mm on it straight and square and ALL THE WAY ON... Then make sure you are pushing & keeping the socket on. I think you can get it without having to drill it or get special tools. Special tools might not fit in there any better.

Don't worry. The universe is just telling you to slow down and finish tomorrow

 

^^^THIS^^^

The exact same thing happened to me, on the exact same bolt, when I did my timing belt/water pump. And the bolt extractor worked for me.

https://m.lowes.com/pd/IRWIN-BOLT-G...EO_NJ1OXulhb-xWO3GttRwrn3Cpo9RikaAsY9EALw_wcB

 

I forgot... if none of the above works a SHARP small chisel has been successful a few times for me in the past. Start it at 90 degrees to the bolt head and make a small "V" then insert the chisel into the V and tap it counter clockwise.

 

x2 to this. Had to use one this week I borrowed from a buddy. Tapped it on with a hammer and that thing never budged until the bolt broke loose.

 

I'll throw out another tool idea. It may or may not help in this situation. Socket caps. They allow you to use a socket in places without enough clearance to fit the ratchet.

If you're going to harbor freight to get that other tool consider picking these up too. Only $3.99 and good to have in the toolbox.

 

Spray some penetrating oil on the top side threads there.
I'd there find a socket just a hair smaller and beat it on.
Or just grind it off and remove the bolt with voice grips after the tensioner is removed