Rear pinion shaft bolt-shaved head

[manousos]

I was following the steps to change the rear axle bearings and seals from this thread
http://www.explorerforum.com/forums/showthread.php?t=214805

unfortunately the pinion shaft bolt refused to move, and the head shaved (rounded) in the 9mm wrench (EDIT:it was 8mm) that I was using


How do I get this out?!

 

[Blee1099]

Umm.. got a pic of what it looks like not the one from the other thread.. If you shaved the head off, the only thing I can think of is to weld a nut on it if you can get access to a welder.. Also try some heat.. Use a torch and heat up area then try it.

 

[Cobraguy]

What's worse is the bolt may be broken once you get it loose. Hope not.

You can try to beat a socket on there that is slightly smaller. Or beat it partially on there and weld it. I don't think there will be room to weld a nut on there is there? If all attempts to remove the bolt fail, you have two options. Run it like it is without changing the seals, or spin the diff 180 degrees, take a large punch ( I use a cross shaft about the same size) and one BFH, and beat the snot out of it and drive the shaft out. This will destroy the differential, but it will work. There are tools to remove this bolt if it's broken, but if you can't get it to even unscrew, you are in trouble.

 

[boominXplorer]

I would try an 8mm or 5/16.

 

[manousos]

Actually I used an 8mm - I entered 9mm in error in the original post.

I got in touch with Nicki Fabri from Fabri Associates who manufacture an extraction kit. Very quick and great communication - unfortunately their kit only works on broken bolts, which does not apply to my situation.

They recommended using bolt extractor. Irwin and Craftsman make them - I'll have to take a look and see if they even fit. Not much clearance in there....

 

[Green betty]

I'm having same problem getting that bolt out. I have not rounded it yet. Any tips as to how I can get that bolt out?

 

[Turdle]

I'm having same problem getting that bolt out. I have not rounded it yet. Any tips as to how I can get that bolt out?

Try to get the bolt ice cold.

 

[Cobraguy]

That is an interesting solution Turdle...and I can see where that might really help! To get it cold, grab a can or two or 134A, use a can tap to spray it. Just don't tell the EPA...

 

[Green betty]

That is an interesting solution Turdle...and I can see where that might really help! To get it cold, grab a can or two or 134A, use a can tap to spray it. Just don't tell the EPA...

Lol any tips for lack of space in there I can't get anything in there to loosen the bolt my socket started to skip the bolt I really don't wanna strip it.

 

[MrQ]

the deal with the pinion shaft bolt is you must get the bolt head clean of all oil and you must use a high quality 8mm box end (Use the 12 point side so it fully encapsulates the head of the bolt). The higher quality stuff has tighter tolerances so there is less chance of slippage. Worst comes to worse find a 7mm socket or a 1/4" 12 point and smash it on there. Use a 1/4 drive extension and a wobble and start cranking.