So the dreaded torx bolt stripped out on my 06 Mini S on the front rotors. Stupid design if you ask me but turned an hour job into like 3 and still have one bolt stuck in. Anyone got any ideas to get this thing out? I think I am going to go back and take the side off that went smooth and remove that bolt so next time this does not happen. Here is what I have tried so far:

Let it soak, heat it up, stripped it out. Pounded a larger torx socket on it, got a huge grip on it and stripped it again. Drilled it, tried to use an easy out and snapped the bit off in there. Not sure what else to do now except get the die grinder out and try cutting that bolt and hopefully not hit the hub.

Let me know what you guys think?

 

i asked a mechanic at the dealership how they get them out and how much trouble they have

he said they use a 3/4" air impact driver with an impact torx socket driver and it never fails to remove them

he also said hand tools will fail more often than not

scott

 

After I get this one out, I will not be putting them back in. I would do that but it is round now so I can even get a the large torx socket to grip on it.

 

Folks have had good success with these too, provided you can come up with the proper bit:

Craftsman Manual Impact Driver

Halfords Manual Impact Driver

Lisle Manual Impact Driver

Although it sounds like your remaining bolt might be too far gone for this approach. Hope you find success.

 

Before drilling the head off, I'd take a DREMEL tool and slot it, then use a hammer and chisel to hit it counterclockwise and, hopefully, break it loose.

 

I had the same problem with one of mine but heat did the trick. Just a tip, put anti-sieze on the threads when you put it back in. You never know when you might need to take it off again.

 

Get a dremel, cut a slot that fits a LARGE straight screwdriver that has a square shank, insert screwdriver, push hard IN while at the same time turning the shank of the driver with a crescent wrench locked on square shank.
My large Craftsman straight blade has a width about the same as that screw...about 1/2" and a 3/8" square shank.
I used this technique a few times on these and has not failed me yet.

 

i just drilled mine out. on the front rotors. and haven't replace them yet, don't plan to either.

 

Thanks guys, got it with a buddies air hammer.

 

Try a bit of heat, then some penetrating oil? The expansion of the metal helps break the rust and draw in the oil....

 

Why Mini uses wheel bolts versus studs is beyond me. I think they go overboard trying to be quirky sometimes. At any rate, that's the reason they have a need for that stupid bolt in the first place. It does help the process if you have something to hold the rotor in place during assembly. Luckily, I had no problem with any of my 4 bolts, and I spent 4 months living right on the ocean. So I was a little concerned. I would think an easy out would make short work of it. Good luck!