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Old 06-28-2004, 06:40 PM   #1
Keshav
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1998 GC8 Unicorn
MV Agusta Brutale S

Default Installing Cruise Control Kit - stripped square bolt

So, I got as far as the part where you remove the bolt that is on one of the intake runners to replace it with a vacuum hose nipple. The bolt is square and my 7 mm open-ended wrench fit ok, but I had to move up to 8 mm to get a closed-end on it. It stripped rather easy.

I am sure that some kind of loc-tite was used during assembly since the new part has white stuff in the threads. This is an OEM kit that I bought and all the parts/instructions are Subaru.

So, is there a trick to getting this bolt out? The metal seems real soft, maybe low-grade steel. It's a square shape and is somewhat longish .. maybe a cm or 1.5 cm. I could file it square again, but I don't have anything smaller than 7 mm.

I want to avoid cutting off the head, drilling the bolt and reverse tapping it. is there another way?
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Old 06-28-2004, 08:33 PM   #2
vrg3
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Default

Yeah, those square-head plugs are annoying.

That white stuff is sealant for the pipe threads. It may also be an adhesive, I guess.

Vise Grips (actual name-brand Vise Grips, not no-name locking pliers) worked for me...
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Old 06-28-2004, 09:20 PM   #3
avk
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Do it on a hot engine using large Channel-lock or Vise-grip type pliers. The pinch should be strong enough for the square end to start squishing. Don't let the tool hit TPS when the plug breaks loose.
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Old 06-29-2004, 04:22 PM   #4
ultrasonic
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Default

We totally mangled one on my friend's OBS a couple years ago. Never did get it out. He eventually just put a splitter on a vacuum hose off the manifold and used that instead of the square plug.
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Old 06-29-2004, 08:55 PM   #5
Tim Sanderson
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Blue Ridge Pearl

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Try a crescent wrench on it before you mangle it any more. Most decent tool stores will carry female square head sockets.
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Old 06-30-2004, 03:20 PM   #6
STS2.2
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The 7mm open end wrench worked fine for me this past winter when I did the same thing you are doing. You didn't need to use the closed end of a wrench on it but now I would just get some locking plyers on it, vise grips work great, lock them on there tight and turn it to loosen it. Should work fine. It may be helpfully to run the engine to get it warm, not hot as it is a pain to work in there then.
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Old 06-30-2004, 03:22 PM   #7
vrg3
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If you are using closed-end wrenches or sockets, they should be either 4-point or 8-point. 12-point and 6-point wrenches/sockets aren't designed to fit over squares.
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Old 06-30-2004, 08:45 PM   #8
Keith99RS
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If the white material on the threads is to act as a sealer it is likely teflon tape. That shouldn't bind the bolt in any way. If you use vise grips or a better wrench, try nudging or rocking your torquing pressure instead of just leaning into it. The nudging action seems to break bolts free better than just cranking on it.
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Old 06-30-2004, 10:03 PM   #9
avk
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OK, so how did it turn out?
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