02, 5.9l, AWD

Need some advice... The head of one of my brake calipers bolts (aka mounting pins) is stripped. As far as I can tell, they are OEM, but they are somewhere between 6-7mm or T40-T45. Anyhow, does anyone have a suggestion for removing it (tried and true... not some hypothetical BS that might work in another dimension)? I bought replacements. They are 7mm.

I have tried various sizes of hex wrenches and even some of the odd-ball bits that come in misc drill bit kits. These ventures just made it worse. I also tried gripping it with locking plyers. No dice...

Would an EZ Out kit work for this? I really don't want to destroy the caliper in the process?

 

http://www.harborfreight.com/catalog...bolt+extractor

try any of these (if you have a store near you) iirc you can get something around the outside of the round head on the brake caliper bolt, and that should let you get it out. (we have done similar jobs on our FSAE car at school with great success)

EDIT: this will only work if it is the head that is stripped out.

 

I've seen the misc extractors. I was curious if anyone had better experience with one over another... or a simple idea I haven't thought of. I have a generic drill out/ extractor kit, but it doesn't seem practical in this setting.

I'll take a look at the extractor sockets. I think the pin is too round and smooth for those to be of any help though.

Thanks for the suggestions.

 

If you have to go with the EZ out, use the largest one humanly possible. I have broken nunerous small ones, last one on a bleeder screw. Broke off where I couldn't get a hold of it, so new caliper time. Start dead center with a small drill bit and keep moving up until you can get a decent size extractor to use. Anyone near you with a small MIG that could tack it to another bolt head and then try to remove?

 

Had the same problem years ago when I did my brakes. Couldn'd find the right size socket to get the bolts out. Bought a new bolt and matched it up. I seem to remember it was an odd ball size and not all the parts stores had it. I think I ended up going to Napa and they either sold it seperatly in a bubble pack in there "special tool section" or it was part of a "brake tool assortment"

 

Actually tacking another bolt head on isn't a bad idea, but it would take someone skilled with a welder.

 

I like the idea of tacking another bolt on, but I don't know anyone. I'll get back when I figure it out. Unfortunately, I am going to have to put it on hold for now. It's the end of the weekend and I have other things to deal with. My brakes are fine, I just wanted to smooth out the mounting slides. They have developed grooves.

 

Perfect reason or excuse if you are married to buy a 120V MIG. You don't need to be a rocket scientist to use a MIG. Bought my 1st one at age 58 to weld up a cat convertor on a jeep. No classes or books. I wouldn't think of doing major structural work but then a 120V MIG couldn't do it either. Someone selling a used one might come over to show you how it works on your bolt!

 

you could try taking a hacksaw or dremmel with a cutting disk and cutting notches for a big flat head screw driver... ive had that work before...

 

UPDATE:

I finally got it out. I hammered a cheap 1/4" hex wrench as deep as I could into the bolt. It actually grabbed... (the wrench won't come out now though )




I ground the plates smooth; now the cluncking sound is gone.



Also, the new caliper bolts, with lots of grease, eliminated the sqealing sound I was hearing too. Super quiet brakes again.


(side note regarding all the talk about rust lately... that hub was shiny and new a year ago. Now look at it. Gotta love the salt.)