Installing Cruise Control Kit - stripped square bolt

Keshav · 06-28-2004, 06:40 PM

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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vrg3 · 06-28-2004, 08:33 PM

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...

avk · 06-28-2004, 09:20 PM

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.

ultrasonic · 06-29-2004, 04:22 PM

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.

Tim Sanderson · 06-29-2004, 08:55 PM

Try a crescent wrench on it before you mangle it any more. Most decent tool stores will carry female square head sockets.

STS2.2 · 06-30-2004, 03:20 PM

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.

vrg3 · 06-30-2004, 03:22 PM

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.

Keith99RS · 06-30-2004, 08:45 PM

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.

avk · 06-30-2004, 10:03 PM

OK, so how did it turn out?

06-28-2004, 06:40 PM	#1
Keshav Scooby Specialist Member#: 1654 Join Date: Jun 2000 Chapter/Region: NWIC Location: Seattle, WA, USA Vehicle: 1998 GC8 Unicorn MV Agusta Brutale S	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? * Registered users of the site do not see these ads.

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06-28-2004, 08:33 PM	#2
vrg3 Scooby Specialist Member#: 25796 Join Date: Oct 2002 Location: Cleveland, OH (sometimes DC) Vehicle: 1993 Legacy Turbo Burgundy	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...

06-28-2004, 09:20 PM	#3
avk Scooby Specialist Member#: 17252 Join Date: Apr 2002 Chapter/Region: Tri-State Location: NJ Vehicle: '06 WX8 59E	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.

06-29-2004, 04:22 PM	#4
ultrasonic Scooby Newbie Member#: 18006 Join Date: Apr 2002 Chapter/Region: MWSOC Location: St. Louis, MO	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.

06-29-2004, 08:55 PM	#5
Tim Sanderson Scooby Guru Member#: 6486 Join Date: May 2001 Chapter/Region: MWSOC Location: S.E. wisconsin Vehicle: 00 Impreza 2.5 RS Blue Ridge Pearl	Try a crescent wrench on it before you mangle it any more. Most decent tool stores will carry female square head sockets.

06-30-2004, 03:20 PM	#6
STS2.2 Scooby Newbie Member#: 52875 Join Date: Jan 2004 Location: Milford, DE Vehicle: 1999 OBS Silverthorne (2-tone)	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.

06-30-2004, 03:22 PM	#7
vrg3 Scooby Specialist Member#: 25796 Join Date: Oct 2002 Location: Cleveland, OH (sometimes DC) Vehicle: 1993 Legacy Turbo Burgundy	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.

06-30-2004, 08:45 PM	#8
Keith99RS Scooby Specialist Member#: 9243 Join Date: Aug 2001 Chapter/Region: NESIC Location: Suffield, CT Vehicle: 05 Nissan Titan 06 B9 (hers)	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.

06-30-2004, 10:03 PM	#9
avk Scooby Specialist Member#: 17252 Join Date: Apr 2002 Chapter/Region: Tri-State Location: NJ Vehicle: '06 WX8 59E	OK, so how did it turn out?