valve covers?

[gc4vette]

I'm in the middle of changing my valve cover gaskets and i'm on the last bolt on the back cover and it stripped !! wtf!! Any suggestions on what to do ? How do i go about getting this last one out?

 

[luigisho]

Well that really sucks. Soft aluminum= be careful. Which bolt broke and where on the bolt did it break?

 

[gc4vette]

The bolt didn't break just the hole is stripped

 

[luigisho]

Can you break the top of the bolt to get the cover off and deal with the rest that way?

 

[jthomas68]

The valve cover bolts like to stick.I tap on the top of the Allen wrench as someone else turns the bolt.Try to slot it and use a large screwdriver.You really don`t want to drill the head off unless you have to.The bolts are close to $20 a piece.

 

[pjtoledo]

gc4vette:
I'm in the middle of changing my valve cover gaskets and i'm on the last bolt on the back cover and it stripped !! wtf!! Any suggestions on what to do ? How do i go about getting this last one out?

Not sure if I would try this while the bolt is still on the engine but,,get another allen wrench, one that is a little bigger, and cut about an inch off. On one end use a hi speed mini grinder to make the edges as sharp as possible. NOT POINTED,,,just the sharpest straight cut you can do,,then hammer that piece into the stripped out hole, it will cut new slots. Like I said, not sure I would do this on a soft aluminum head though. Might break the head, that would be a real bummer. There is always big pliers, or put a notch in the edge and use a punch to turn it. Good luck.

Perry Toledo,Ohio

 

[rangerj]

I asssume you are talking about the 5 milimeter allen wrench slot. If so, try cleaning as much of the rust as you can. Then, try the next size allen wrench in standard sizes, not metric.

I have used a Dremel tool with a small grinding bit to slightly enlarge the slot to fit the wrench. I have also had a limited amount of luck with putting a layer of tape on the 5 mm wrench so that it fit tighter in the slot. If the bolt is in really tight, this may not work.

You can try an "easy-out", but the hole may not be deep enough for the tool to get a good "bite". Sears has been advertizing a new tool for extracting a broken bolt. It is a set of drill bits with an extractor.

You already have a hole, so all you should have to do is "thread" in the extractor while running the drill in reverse. The torque from the drill should back out the bolt.

I have used this tool for extracting broken bolts, and it does work as advertised.

As a last resort you can use a Dremel tool to cut a slot in the bolt head for a screwdriver.

Whatever method you choose, you want to do as little damage to the valve cover and/or head as possible, so approach this with a lot of care and thought. Replacement parts for these cars are sometime hard to find, and expensive when you do find them.

Any of the bolts that are rusted that bad should be replaced. You my be able to get a few good used ones from another forum member, as new ones are about $20 each.

See the post about the "granaded motor". From the looks of the pictures that member may have about 20 extra valve cover hold down bolts (16 long + 4 short).

When you put the valve covers back on, be sure to use a torque wrench on the hold down bolts. These bolts are easily broken if they are over tightened. Put a coat of clear coat, or clear nail polish, (do not let your wife see you do this)in the slots after you torque them. rangerj

 

[sdpatt]

I have used a hammer to tap a tight fitting Torx bit into the stripped bolt's head. The Torx bit has better grabbing edges than the smoother Allen bit. Please use a torque wrench set at 8-11 lb-ft when you reinstall those bolts.

 

[gc4vette]

Got it out with vise grips!!

 

[SnickterP]

heh, very creative