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Old 12-24-2005, 05:42 AM   #1
AVANTI R5
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Default Bolts(heads) snapping off,removal

Every time I go to work on my 04 STI,when removing bolts esp. the #10 for the under tray (oil changes) the head of the bolt(about half way) just snaps in half.They are kind of rusted from winter salt but still.Anyway now I have several bolts snapped and I got to get them out,so I can get my under tray back on.What is the best way to get these out,I saw the post about the sears kit,anything better? tips,etc ? Thanks!
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Old 12-24-2005, 06:08 AM   #2
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If this happens to you every time you work on the car, why haven't you tried using anti-sieze on the bolts when you put everything back together? If the threads are truly galled, the sears kit and some heli-coils are in your future Are you making absolutely sure that the bolts aren't being cross threaded when you replace them? Anti-sieze is your friend.
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Old 12-24-2005, 06:19 AM   #3
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They break off during removal and some are the first time they were removed from the car
brand new.They are really poor quality bolts
there all rotted and rusted already.
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Old 12-24-2005, 06:37 AM   #4
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you probably won't be able to hit the splash shield bolts with PB Blaster without hurting the plastic, but use that stuff whenever applicable at least 30 min before you start wrenching.
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Old 12-24-2005, 10:22 AM   #5
jac04
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I put anti-seize on those bolts at the first oil change and I have never had a problem. Make sure that you do not over-tighten them - they really don't need to be that tight.
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Old 12-24-2005, 11:10 AM   #6
Hayes
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Tighten them to only 3-4 ft/lbs and you should have no problems.
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Old 12-24-2005, 01:45 PM   #7
AVANTI R5
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Thanks guys,Yeh I think that is one of the problems(I am over tightening when replacing).I am going to get all new bolts and those plastic fasteners and start with fresh bolts with anti-seize on them. I hope I can get these broken bolts out,easily. Thanks for the help!!
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Old 12-26-2005, 05:57 AM   #8
John UK
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Try using stainless bolts.
They are not in a strength critical application and won't corrode. You may still need to use some anti corrosion prtection to stop the internal threads rusting as well.
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Old 12-26-2005, 08:19 AM   #9
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Quote:
Originally Posted by John UK
Try using stainless bolts.
They are not in a strength critical application and won't corrode. You may still need to use some anti corrosion prtection to stop the internal threads rusting as well.
These are not an off-the-shelf bolt. They are a shouldered type bolt that will not crush the plastic under tray. It would be almost impossible to find a stainless replacement at your local hardware store.
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Old 12-26-2005, 10:57 AM   #10
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Quote:
Originally Posted by jac04
These are not an off-the-shelf bolt. They are a shouldered type bolt that will not crush the plastic under tray. It would be almost impossible to find a stainless replacement at your local hardware store.
Yes I remember them now and you're right.
I do have the advantage of a lathe so can either make the bolts or (more likely) a loose collar to fit a standard bolt.
However, stainless shoulder bolts are available - if rather rare.
Try this link
http://www.rinomechanical.com/shoulder-bolt.htm
Obviously I've no connection at this distance. They just turned up in google search for "shoulder bolt" and "stainless".
I've not checked sizes etc but it may help.
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