I tried removing the pinion shaft bolt on a rearend I'm rebuilding and I rounded the *&%#!!! bolt head. I used a 6pt box wrench and socket, but cracked the socket and rounded the head. I've torched it with MAP gas, drilled a hole thru the side of the head in hopes I could insert a punch thru it and wack it with a hammer but all I do is break/bend punches and throw stuff! This isn't gonna beat me! Any suggestions are greatly appreciated.

 

Go to your hardware store and buy one of those nut cracker things. Its like an oversized socket you wack on with a hammer and it has teeth that grabs the rounded bolt then you just take it off with a big wrench. I remember when i took out my pinion i had a shop use air tools to take it off cause the damn thing wasnt moving.

 

thanks....hopefully there's one that will fit. I have a rounded bolt remover set but it's too big 4 this bolt.

 

This bolt is in a tight place and it's hard to get to it. I think I've used a chisel before to break them loose. I have a special 6 point wrench that I use because I rounded off a few with a 12 point.

 

use an electric impact if you don't have access to the proper air supply. you can rent a real heavy duty one from a local rental. use a 3/4 incher with a reducer to 1/2 and use your broken socket. weld the socket to the nut carefully with a tack on all sides.
just some random thoughts.

 

Thanks guys....I had success with blasting the bolt/casing for about five minutes with a torch til the bolt was cherry and then stuck a small phillips head thru the hole I drilled and gave it a wack and it busted loose.