Ignition barrel sheer bolt removal

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jl45

Member
Posts
22
Location
Lakenheath
Trying to remove the ignition barrel from my 200tdi but am have a bugger of a time. The bolts look like the ones in the link and in fact still have the bolt head on them. From what I've been reading these are supposed to snap off. I tried turning as is but they wont budge. Drilling provided a decent hole for a bolt extractor but ended up snapping that off. So now have hardened steel in the hole. Is my only course of action to drill that or maybe cut off the ends and try drilling again? Thanks for any help.


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Cut through the middle of the bolt where the alloy casings meet with a grinder & thin metal cutting
disc or use a dremel with the 22mm discs ;)
 
Its very tight I just had another look at mine iirc I removed the lower dash & lowered the steering column
(eventually as I have a small cut in the lower dash from a grinder lol

May be best with a dremel !!
 
I don't know if the D1 is the same as the D2, but when I had to remove the security bolts holding the steering lock, I did it with a chisel.
I first used it to bash a bit of a nick into the edge of the bolt head and then I was able to gradually change the angle of the chisel so that the action started to undo the bolts.
Bit of a faff and it took a bit of patience but they did come out without having to resort to drilling, stud extractors, cutting discs, et al.
Just because you're using a hammer and chisel, it doesn't mean you have to get all violent and try to knock the head of the bolts off.
 
I don't know if the D1 is the same as the D2, but when I had to remove the security bolts holding the steering lock, I did it with a chisel.
I first used it to bash a bit of a nick into the edge of the bolt head and then I was able to gradually change the angle of the chisel so that the action started to undo the bolts.
Bit of a faff and it took a bit of patience but they did come out without having to resort to drilling, stud extractors, cutting discs, et al.
Just because you're using a hammer and chisel, it doesn't mean you have to get all violent and try to knock the head of the bolts off.
This is what I did anorl, just about. Cut a slot in the top with a junior hacksaw and put an old screwdriver in and tapped them around.
 
Found a picture and it reminded me of what I actually did.
I didn't cut the slot with a junior hacksaw, I scratched it in with the screwdriver, then tapped it around until it was slack enough to turn. The metal is soft enough to scratch a groove in.
Ignition Barrel Bolts.jpg
 
Thanks for replies everyone. I'll give it another go with your suggestions but I think getting the heads off is step one if they continue not to turn. Appreciate the feedback, back at it.
 
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