rounded head on bellhousing bolt???? - JeepForum.com
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Unread 04-12-2010, 07:12 PM   #1
wildride89
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rounded head on bellhousing bolt????

i have been having issues with my jeep and with the help of this site and my neighbor it was narrowed down to the throwout bearing. i purchased a clutch kit from the neighborhood advance auto which came with the slave cylinder/bearing, pilot bearing/bushing pressure plate, alignment tool and clutch plate. i have never attempted removing transmissions or anything like that before but i figured what the hell and decided that it would be a good learning experience. i have since removed the front rear driveshafts, various lines to and from transfer case, the brake line from cylinder in bellhousing, exhaust since i couldnt clear the removal without it, and finally arrived to the point to where the bellhousing had the mounting bolts left in that. i removed the 6 bolts around the side and didnt know there was two more bolts at the top which my neighbor pointed out to me and he offered to help and didnt turn it down. since he has a jeep and has had one for a long time i figured he knows way more than me and he proceeded to try and take them out. turns out he thought that they were one size and it turned out to be inverted star heads and he ended up rounding off the head before i got back from the store with the set of star sockets. my question now is does anyone have a good idea as to how i can get that top left bolt out???? its definitely stripped because i put the right size socket on it and it was already too far gone. any ideas or info is appreciated thank you

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Unread 04-12-2010, 07:18 PM   #2
Burnerman
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Weld a nut on it. Those 2 bolts are 2 I hope I never strip. They are a PITA to even see. If you drop the trans down on a jack and remove the shifter cover you can get to them better. You could try to pound a cheap socket on it. Those 2 bolts get the highest torque when they get tightened so they're in there.
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Unread 04-12-2010, 07:25 PM   #3
YJake
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Gah... I've had to mess with those too many times on 4.0 rigs!

My advice would be to let the tranny sag so that you have more room to work with in there and try to either weld a nut on the end or..... Hrmmms..... Drill it out?

Good luck, I feel your pain!

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Unread 04-12-2010, 07:58 PM   #4
jay-h
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I was just in Home Depot the other day and saw a special socket for digging into and removing rounded head bolts. Can't tell you how well it works, though. I have successfully used a small pipe wrench on rounded heads, but you need some clearance for the wrench.
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Unread 04-12-2010, 08:04 PM   #5
little_Jeep
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Quote:
Originally Posted by Burnerman View Post
Weld a nut on it. Those 2 bolts are 2 I hope I never strip. They are a PITA to even see. If you drop the trans down on a jack and remove the shifter cover you can get to them better. You could try to pound a cheap socket on it. Those 2 bolts get the highest torque when they get tightened so they're in there.
X2 on the above advice.......... once you get those bolts out, toss them in the trash and replace them with some nice hex bolts.
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Unread 04-12-2010, 08:08 PM   #6
erockz
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Buy these. They work amazing. Trust me I own them and am a mechanic. I use them all the time. A must have in your toolbox. http://www.sears.com/shc/s/p_10153_12605_00952166000P
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Unread 04-12-2010, 08:11 PM   #7
Burnerman
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^^^ x2 I just thought about them. I have used them a couple of times and they just might work.
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Unread 04-12-2010, 08:12 PM   #8
Louie4
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The torx head bolts on the top of my AX-15 rounded. I lowered the tranny and took an old 3/8 socket, unknown brand, and tapped it over the bolt head with a hammer then I was able to get it off.
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Unread 04-12-2010, 08:49 PM   #9
wildride89
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thanks guys youre the best also the freaking flange coming down from the exh manifold i sheared off that bolt too but i guess what can you expect hardware conditions to be on a 21 year old jeep thanks again im going to give you an update when i get back to it
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Unread 04-13-2010, 05:20 AM   #10
Louie4
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Quote:
Originally Posted by wildride89 View Post
thanks guys youre the best also the freaking flange coming down from the exh manifold i sheared off that bolt too but i guess what can you expect hardware conditions to be on a 21 year old jeep thanks again im going to give you an update when i get back to it
I think Autozone has some replacement studs you can get.
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Unread 04-13-2010, 06:19 AM   #11
Nucklez
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Quote:
Originally Posted by erockz View Post
Buy these. They work amazing. Trust me I own them and am a mechanic. I use them all the time. A must have in your toolbox. http://www.sears.com/shc/s/p_10153_12605_00952166000P
I was going to post the same set man! I have some of those, and had to use them when getting the exhaust off of the manifold. They were actually strong enough to break the bolt in half, even though the head was rounded off! Those things are amazingly strong! By the way, even my local machine shop couldn't tap the rest of the bolt out of the manifold. He had to drill and tap me another hole right beside that one.
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