Stripped Bolt

[Agfoxflyer]

Today in trying to remove my gear box, I removed all of the metric hex head bolts but the last one. It is one of the larger bolts at the bottom of the gear box. Unfortunately I stripped it out. Would a screw extactor work? The torgue value of these bolts are pretty high. I thought about cutting a slot in the top of the bolt and using a large screw driver. Any help or advice would be appreciated. Oh the engine is a 912ULS.

[Breathless]

I have cut slot into the head before with good results. I used a Moto tool(Dremal) with a small cutoff wheel, then used a flat bit driver that fits tight. Sometime a sharp blow with hammer to the driver. If the bolt has been installed for a long time, I heat the fastener before trying to remove.
Extractors would be my next thing to try. But if you haven't used them before the correct size drill is very important. I use a small drill bit first to keep in the center of the bolt.
Good luck

Jim

[Av8r3400]

If you are talking about a socket head cap screw (Allen head - that's what is on my 912's), you can often tap in a high quality "Torx" driver, of the appropriate size, into the stripped socket hole and it will bite enough to remove the screw.

If you can find one, I've used impact torx sockets like this with good results.

[Mark]

I have used 'easy outs' with good success. Also, heating the bolt will help loosen any thread locker on it.

[t j]

There are some allen head bolts in the Rotax gear boxes that are not your ordinary allen head. Using an ordinary allen wrench will risk stripping them. You need an "Allen key with pilot". There is a nose on the end of the wrench that fits into a hole past the hex hole in the head of the bolt. This keeps the wrench absolutely straight in the hex hole. Those bolts are very hard to get out as they probably have some exotic and expensive lock tight on them.

Here's a picture of the allen key with pilot
http://www.ekmpowershop2.com/ekmps/s...-c-e-613-p.asp

[Slyfox]

those bolts must have locktite on them, than again it just may the case of aluminum and steel bolt syndrome. If you stripped out the head, do what you can to get a hold of it, I'd have to look at mine to see what your talking about. But before I tried removing it I would heat it up good to melt the locktite or other, if it were me I would use a oxy torch get the bolt red and than try again. I've had to remove many a bolts that didn't even have the locktite with the housing aluminum and that was the only way. I also found another trick and that's to heat the head up red and than smack the screw or bolt with a punch or socket on the head with a hammer. You only want to go until the head turns read don't let it melt down.