Help with caliber mounting bracket stripped bolt

[nitroman]

So worked on the rear brakes last night and the caliper went off fine, but then when I got to removing the caliper mounting bracket (so that I can remove the rotors), but found that the top bolt is a bit stripped (argh, can't remember which shop did the brakes last time). Not entirely round, but enough that I couldn't get a good grip to get them off. The bolt is an 8mm allen key bolt. It's round on the outside and has a 8mm hex on the inside. So:

1. Any suggestions? Note that this is the top bolt and it's behind the rotor, so there's not a lot of room to work with here (I dunno if I can fit a drill or anything).
2. Would these bolt extractors work?
Mastercraft Extract-it 5-piece Set | Canadian Tire

3. Does anyone know the exact size of the bolt so that I can get a new one? I know I could wait until it comes out then take it to the HW store and match it, but it'd be nice if I can have an exact spec and buy it before so I don't have to run back and forth.

Thanks.

[IndyTom]

Never used bolt extractors so I can't say if they will do the trick or not. They should if they do as they advertise as long as you get the correct size.

Did you try a pair of Long nose Vice grips? I would soak the bolt in some Seafoam Deep Creep (Best solvent when it comes to loosen bolts) then let it sit for a few minutes and then the bolt should come right out.

Seems you are running into all sorts of little issues. Hope the rest of your project will go more smoothly!

[300exoh]

Originally Posted by nitroman

So worked on the rear brakes last night and the caliper went off fine, but then when I got to removing the caliper mounting bracket (so that I can remove the rotors), but found that the top bolt is a bit stripped (argh, can't remember which shop did the brakes last time). Not entirely round, but enough that I couldn't get a good grip to get them off. The bolt is an 8mm allen key bolt. It's round on the outside and has a 8mm hex on the inside. So:

1. Any suggestions? Note that this is the top bolt and it's behind the rotor, so there's not a lot of room to work with here (I dunno if I can fit a drill or anything).
2. Would these bolt extractors work?
Mastercraft Extract-it 5-piece Set | Canadian Tire

3. Does anyone know the exact size of the bolt so that I can get a new one? I know I could wait until it comes out then take it to the HW store and match it, but it'd be nice if I can have an exact spec and buy it before so I don't have to run back and forth.

Thanks.

I would measure the outer diameter of the bolt head before ordering. According to the product Q&A they come in certain sizes and apparently there is another kit available with different sizes than the one you posted. You'll want to get an extractor that matches that outer diameter as closely as possible or it either won't fit over it or it will just spin and not bite to the bolt head. Hope that makes sense.

You might have luck with something like this...http://www.canadiantire.ca/AST/brows....jsp?locale=en

Or this (but not sure what size you would need)...http://www.canadiantire.ca/AST/brows....jsp?locale=en

[Opelmania]

I had the same thing happen on my friend's 99 when I did his. Must be something with the 99's cause I didn't have an issue on my 98. Anyway, I ended up heating up the bolt with map gas and used a big pair of regular vise grips to get it off. I tried to use the bolt extractor and one was too small and the other was too big. Of course I found out after I bought the kit. I ended up going to my local Ace Hardware store and got a new metric bolt from there. I can't remember what size though. Sorry. Good luck getting it off.

[300exoh]

This might even be your best bet...Mastercraft 5-piece Screw Extractor Set, Sizes #1-5 | Canadian Tire

[Opelmania]

I don't think you'll have much luck with the pointed extractors. There isn't enough room back there and with the heat and rust, those bolts get fused pretty tight. This is the kit I bought Irwin/5 pcs. 3/8 in. drive Bolt-Grip expansion extractor set for 5/16, 11/16 and 3/4 in. or 8, 10, 13 and 19 mm. bolts (394002) | Bolt Extractor | AutoZone.com but ended up just using heat. I learned from stripping the first side to heat up the other frozen bolt before I stripped it.

[nitroman]

Wow thanks everyone for all the response. This ORG is great!

@300exoh and @Opelmania: I have a set of the spiral screw extractors but not the bolts one, didn't try it yet though because I didn't want to mess up the middle hex part even more and I didn't know if there was a way to salvage it. As I said it's only slightly rounded, not entirely, but just not enough edge for me to get a good grip as it's torqued on there pretty tight. But as Opelmania said, I'm not sure if I'll be able to fit a drill back there and get it lined up properly to use the spiral extractor. I guess maybe I'll try the bolt extractor one that fits on a socket. I don't have access to heat, so I'll try a penetrant. I have a bottle of CRC freeze off, will that work? Or is it better to get seafoam deep creep?

CRC/Freeze-Off super penetrant (05002) | | AutoZone.com


Oh and 300exoh thanks a lot for giving links to the CanadianTire site, that helps a lot . We don't have a lot of good auto parts store up here.

@Tom: Sigh yes I'm running into a whole bunch of little problems. But I expected it as this is my first real DIY project (ok I did oil changes but that doesn't count), and I'm a mechanical noob. I'll take this as a learning experience. But thanks to the ORG for all the help so far, otherwise I'd be majorly screwed and my wife would be sooooo pissed at me for messing up her beetle.

One last question, I had a heck of a time unhooking the emergency brake cable. It was really really hard pushing the lever down so that there was enough clearance to unhook it. How do you guys do it, any tips/tricks?

[VWBubba]

There are many ways to attack the problem, some have been mentioned already:

Vise Grips
Extractors
Heating it
Oil

And the like,

Make sure if you use a socket that you use a 6 sided not a 12 sided as this will round it even more, have you tried beating on a slightly smaller socket or allen key? After a lot of use Allen Keys wear on the ends, re dress it or do as I do and cut them down into sections, this makes them easier if you need to hammer one in. Not much hope with a spiral stud extractor as the head will not have enough to get a grip, try the extractor with roller inserts if you have one.

Another method I have used is to use a 'nut splitter' this will dig into the side and give you some grip, failing that a hammer and chisel almost never fails .. Give it a good spray with anti seize and leave over night, then tap it round anti clock of course with a sharp cold chisel, once you get even the smallest turn you will find the Allen key will finish it.

I have done 100s of these over the years and yes they can be a p.i.t.a but with a little patience they always come out.

Welcome to the forum and welcome to the world of home mechanics .. Remember that scars are like tattoos but with better stories :-)

[Opelmania]

For the heat, just get a can of the yellow gas (MAP) that is by the propane torches. You might have a blue can for your plumbing projects already. The blue can (Propane) will work too, but it will take longer. I had to heat them up for at least 5 minutes, but I was working in a cold garage. I had the exact same problem you are having. I use penetrating oils as well as the heat. Almost forgot about using heat but after beating my head and heads up enough it finally came to me. Even after the heat, it still took a lot of torque to break it free. Good luck and keep at it. You'll get it!

[nitroman]

Hmmmm, no I don't have any torches cuz I haven't tackled any major plumbing projects yet. Maybe I'll start looking into it. So the MAP gas tanks burn a lot hotter than propane?

If I get it I'll definitely have to hide it from the wife, cuz if she sees me playing with fire she'll definitely freak out and force me to give the car to a mechanic . Maybe I'll try those socket bolt extractors first.

But good to hear at least some others have this problem. It seems like almost every DIY project I do around the house, I run into Murphy's law . And I picked brakes to do cuz it was *supposed* to be straightforward and relatively simple - well it is for everyone else. Oh well at least I'm enjoying it (so far)

[IndyTom]

Originally Posted by nitroman

I have a bottle of CRC freeze off, will that work? Or is it better to get seafoam deep creep?

CRC/Freeze-Off super penetrant (05002) | | AutoZone.com

One last question, I had a heck of a time unhooking the emergency brake cable. It was really really hard pushing the lever down so that there was enough clearance to unhook it. How do you guys do it, any tips/tricks?

You can give that CRC stuff a try. I just swear by the Seafoam Deep Creep. That stuff gets deep into the metal and works miracles. I used it prior to even starting on my brake job and I didn't have any issues getting any of my bolts off. Sometime that stuff works almost too well. Worked on my motorcylce once trying to remove some rusted on bolts that held the headlight lens in place. They bolts came off fine after soaking them in Seafoam for 5 minutes. I changed the bulb and replaced the headlight lens. Put the screws/bolts back in and took the bike for a ride. After about 10 minute the headlight lens fell off. I thought wtf... I stopped and looked at the headlight. All three bolts loosened themselves (probably from the vibration from the bike's 1800cc V-Twin motor) and fell out. Crap, I used some good old duct tape to hold the lens onto the bike until I could get some new screws.
Anyway, Deep Creep does work. I am sure other stuff works too but probably not as well.

I didn't have any problem getting the parking brake cable unhooked from the bracket. I think I used a fork to pry the ball with cable off the bracket. Can't remember for sure. I have done a few more brake jobs for friends on other cars since then

Good Luck and I hope you will git er dun!

[IndyTom]

Originally Posted by nitroman

Hmmmm, no I don't have any torches cuz I haven't tackled any major plumbing projects yet. Maybe I'll start looking into it. So the MAP gas tanks burn a lot hotter than propane?

If I get it I'll definitely have to hide it from the wife, cuz if she sees me playing with fire she'll definitely freak out and force me to give the car to a mechanic . Maybe I'll try those socket bolt extractors first.

But good to hear at least some others have this problem. It seems like almost every DIY project I do around the house, I run into Murphy's law . And I picked brakes to do cuz it was *supposed* to be straightforward and relatively simple - well it is for everyone else. Oh well at least I'm enjoying it (so far)

Before I would start playing with fire I would give Seafoam a try Might be a lot safer