Rounded-off Brake-pad Retainer Bolt Removal Suggestions?

[dhawks]

Hey, everyone. I had such success here the last time I posted a question about removing a stubborn bolt, so here goes Round 2:

One of the bolts that holds the brake pads into the caliper (in the attached photo, the bolt that is directly across from the 'o' in 'Tokico') has become rounded-off. A hex/allen key simply spins inside the head of the bolt. As you can see, the bolt lies flush with the caliper surface. How do you remove such a bolt? A friend has suggested driving an appropriately sized Torx bit (or similar) into the head of the bolt and seeing if I could get the bit to impress into the sides and grip.

Thanks for your suggestions.

[Paul_E_D]

Try your friend's idea first, then you basically left with drilling for an easy out.

[ChicknStripEatr]

You're gonna need a new bolt anyway, so you can try your friends idea or you can pick yourself up a screw extractor.

[butcher bergs]

If the Torx bit doesn't work, see about smashing a Standard hex key into the bolt. Throw a little heat on the caliper, concentrating on both ends of the pin, and twist. As an absolute last resort, drill but I feel a little heat is going to do the trick.
The reason why it's stuck is because of galling and is very common with this type of retaining pin style.

[Degsy]

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Nooooooo! Don't heat the caliper!

[butcher bergs]

This I gotta hear....

[Jim]

dustin, when you do get the bolts out, put some anti-seize on them & use the proper hex socket to tighten them to the required torque. you're probably going to need a 4mm or 5mm metric socket, and tighten them to maybe 16.5 ft/lbs

[Jim]

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Nooooooo! Don't heat the caliper!

This I gotta hear....

my guess woul dbe because he could boil the brake fluid & contaminate it. not that replacing the fluid would be a horrible thing. but smashing in a standard sized hex socket might do the trick

[Degsy]

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This I gotta hear....

Rubber seals and piston o rings.

[butcher bergs]

EDIT: I re-read this post and apologise for its precieved tone, hence the complete edit. Not trying to sound dickish and I really don't care what method is used to extract that hardware but based on experience, a little heat will also work.

[Shock3r]

You can get bolt outs at sears for pretty cheap, or borrow mine. I had the same situation when Degsy tried to do my front sprocket. (not his fault, was already rounded out)

Just tap it with a hammer and twist

[Pittenger5]

Can you reach in back with a pair of needle nose and twist the shaft? (giggity)

[butcher bergs]

Sorry Derek and Jim. Post edited. It didn't read quite right.

[ZX11D]

Hey, everyone. I had such success here the last time I posted a question about removing a stubborn bolt, so here goes Round 2:

One of the bolts that holds the brake pads into the caliper (in the attached photo, the bolt that is directly across from the 'o' in 'Tokico') has become rounded-off. A hex/allen key simply spins inside the head of the bolt. As you can see, the bolt lies flush with the caliper surface. How do you remove such a bolt? A friend has suggested driving an appropriately sized Torx bit (or similar) into the head of the bolt and seeing if I could get the bit to impress into the sides and grip.

Thanks for your suggestions.

I tried all that stuff myself on a lower fairing stay that was frozen bad. Stripped it then tried a torx bit and really screwed things up (no pun). Someone suggested a Alden Pro Grabbit kit from sears. Fits in your electric drill and as corny as it sounds it worked just like as seen on TV. Just be sure to get a set (3) thats got one bigger than the bolt thats stripped. It`s that easy. One side cleans things up and the other end gets it out.

[Chippertheripper]

Before you do anything spray some pb blaster on there and let it sit overnite. Do it again in the am. Don't forget to clean that stuff off all braking surfaces upon reassembly. I'd try the sae hex key trick first, myself.

[Degsy]

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That's ok bergs. I learned by experience. Destroyed a master cylinder with heat once, right jim?

[KB]

Get in between the pads with a pair of needle nose vice grips, some PB Blaster and a little luck. NO HEAT. Or I would find a size that is just a shade bigger, and slam it in with a hammer.

KB

[GNTurbo6]

Hammer + Torx bit...

[Pigman]

Those break rather easy......should be easy

[FireboltEric_MA]

I'd put a hex in there and give it a few good wacks, dont be shy, put some oomph into it, pb blaster next, maybe even another whack to try and get it to free up...

then use the hex trick... It should turn right out. been there done that.


Good luck.

[dhawks]

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Many thanks for all the replies. I'll give it a go this weekend or early next week and see if I can gain the ability to change the brakepads.

[Chippertheripper]

If you aren't touching it for a while, start putting the penetrating oil on there now.

[dhawks]

If you aren't touching it for a while, start putting the penetrating oil on there now.

Will do -- probably tonight, in fact.

[dudutzu]

Get in between the pads with a pair of needle nose vice grips, some PB Blaster and a little luck. NO HEAT. Or I would find a size that is just a shade bigger, and slam it in with a hammer.

KB

+1
take the caliper out, push the pistons in so you get more room for the vice-grips, and if you think you gonna have enough room for vice-grips as far as the rotor goes, then put the caliper back on you don't have to hold it and use your both hands trying to get that sucker out

[Jim]

dustin, if you get one bolt out but the other is stuck, see if you can rotate/spin the pads in the caliper to loosen up the stuck bolt. it worked for me reciently