Mrboyle

[Ric94]

94 EX
Doing front axle Ujoints one side no problem, the other side the 2 bolts that hold the anti lock break sensor are rusted to the point where the 6 mm 12 point socket doesn't work.
The other bolt an 8mm 6 point is also rusted but I think I can get that out by cutting a slot and using a screwdriver hopefully. Problem with the 6mm bolt is that its inset and no way get dremel in there to cut slot.
also what can I use to replace the clamps on the rubber boot thats on the two piece shaft?

Any and all help is appreciated

 

[JDraper]

I'm not MrBoyle, but I've got lots of experience in doing what you're trying to do. I'd suggest soaking the bolts for quite a while with PB Blaster (NOT WD-40, it isn't very good at loosening rusted bolts) to try and loosen them a little, and then go buy an easy-out to remove the bolts. An easy out is a hardened steel "screw" with the thread reversed so you can back out damaged bolts. You drill a hole in the head of the bolt, and then screw the easy out in. It bites into the bolt, and then you can put a wrench on the easy out to remove the bolt.

As for the boot clamps, many auto stores sell replacement clamps that you can put on without special tools. I used a pair on my '01 Explorer. You can also use the wire reinforced cable ties. They also will work quite well.

 

[Ric94]

I'm not MrBoyle, but I've got lots of experience in doing what you're trying to do. I'd suggest soaking the bolts for quite a while with PB Blaster (NOT WD-40, it isn't very good at loosening rusted bolts) to try and loosen them a little, and then go buy an easy-out to remove the bolts. An easy out is a hardened steel "screw" with the thread reversed so you can back out damaged bolts. You drill a hole in the head of the bolt, and then screw the easy out in. It bites into the bolt, and then you can put a wrench on the easy out to remove the bolt.

As for the boot clamps, many auto stores sell replacement clamps that you can put on without special tools. I used a pair on my '01 Explorer. You can also use the wire reinforced cable ties. They also will work quite well.

I'm sure your familar with the bolt I'm talking about, the head of it is 6mm and about 1/3 of that is rusted away. I 'm not aware that they make easyouts that small

 

[JDraper]

You might be able to get a #1 easy out into that, they're good down to about 3mm but having that much of it rusted away may require you to drill out the old one and retap it ,which I'm sure is the last thing you want to do.....

 

[Ric94]

Bump

 

[Rhett]

I'm sure your familar with the bolt I'm talking about, the head of it is 6mm and about 1/3 of that is rusted away. I 'm not aware that they make easyouts that small

I am very familiar with the bolt you are talking about. I posted about this before and VERY few people seemed familiar with this bolt. Perhaps it is a 93-94 specific problem. On 91-92s, and Bronco IIs, and pre-93 Rangers it is SO easy to change front u's. On our trucks it's not because of the ABS sensor.

On my truck the 6mm bolt is rusted solid too. It's rusted so bad the head of the bolt is rounded. This is very common, it was like that on 2 1993 Explorers I looked at. Couldn't get any bite with the 6mm socket, or 5 mm etc. On my truck, the 8mm bolt came off, but only with the aid of PB Blaster. The 6mm prevents me from removing the front ABS sensor housing, which prevents me from removing the front axleshaft. I am about ready to drill out the 6mm bolt, and just use the 8mm bolt to hold that sensor in place. That should be enough to hold it...

It's poorly engineered, if you ask me. Any small size (6mm) bolt in a rust-prone location is hardly appropriate...unless its stainless...

 

[Rhett]

You might be able to get a #1 easy out into that, they're good down to about 3mm but having that much of it rusted away may require you to drill out the old one and retap it ,which I'm sure is the last thing you want to do.....

In my case I am hoping that the larger 8mm bolt will be enough to hold the sensor in place. If not, I'll have to re-tap I guess. <sigh>

 

[DeRocha]

All is not lost.
Been there and done that (I just forgot to ge the T-shirt). I mangled one of my 6mm 12pt sensor protector bolts while trying to take if off with my 1/4" socket. I used a drill with a few diff sized bits working my way up in size to erase the bolt head from inside the steering knuckle. I was very careful to NOT drill into the knuckle (which is NOT threaded only the sensor protector is threaded). Once the head was gone I used a screwdriver to gently pry the protector off. To my surprise I found 3/8" of the bolt sticking out. I used a par of vice grips and removed it easily. I went to the hardware store with the ABS protector and bought 2 new Cap bolts (Allen head) as replacements. In the pic below you can see the new and old bolts next to the protector.

 

[Rhett]

I did not want to drill into the knuckle if I didn't have to. That makes me feel better, knowing that I can simply grind the head off. I have been putting off front u-joint work until I figured out the best way to deal with the ABS sensor.

I tore the hub and rotor all the way down in 20 minutes, and spent the next TWO HOURS scratching my head fiddling with that silly ABS housing. Stopped me dead in my tracks. It was so easy on the Bronco II!

 

[Fred Garvin]

Good luck on the bolt.

As far as the rubber boot is concerned, how about using those plastic tie-downs, and cutting the extra off?

AND you should be able to find those cap bolts that DeRocha referred to in STAINLESS STEEL.