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Method to Remove Rusty Rounded Caliper Bolts

Discussion in 'General Land Rover Forum' started by Muse, Jan 8, 2017.

  1. Muse

    Muse Member

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    Hey! I'm looking to buy x4 front caliper retaining bolts for my Disco II. I believe this is them:
    http://www.paddockspares.com/ftc2996-bolt-caliper.html

    They're 19mm double hex part number: FTC2996 Horrible things to remove... I've completely rounded the rusty old ones and now they're stuck... haha. Is there a cheaper bolt to use which isn't a double hex? £17 for 4 is pretty steep... Thanks!
    ---------------------------------------------------------------------------------------------------------
    EDIT>>
    Thanks for all the advise! Managed to get two calipers off and changed the discs and brakes!
    My method using all of your comments to guide me, because when I used a box wrench with hardly any force the ribs completely rounded off.

    1. Wire brush all the crap off the bolt
    2. SOAK in pen oil or WD40
    3. WHACK with a hammer hard many times
    4. To make the bolt fit an IRWIN Bolt Extractor, I used a file (dremel) to give the bolt some edges and small enough to go into the socket.
    5. Keep trying the socket for a decent fit, then hammer into place until fairly tight and deep.
    6. SLOWLY begin to remove the bolt, if the extractor starts to wobble as its spinning, remove ratchet and replace in another position.
    7. It will eventually come off once the socket bites.

    Wow... they're amazing tools. Along with the impact screw driver to remove the disc screw.
     
    Last edited: Jan 10, 2017
  2. jamesmartin

    jamesmartin Well-Known Member

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    you need the proper bolts ,brakes are fairly important, whack the heads hard with a decent sized hammer then hammer your socket back on
     
    neilly likes this.
  3. Muse

    Muse Member

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    Good point mate. I appreciate your advice on my past two posts.
    As for the old one, it was so rusted, on turn of the 19mm double hex rounded it bare. I have some irwin extractor bolt sockets but its slightly too big for them, do you think I could file them smaller then try with another socket? I've been at it for 2 hours! fed up... :(
     
  4. jamesmartin

    jamesmartin Well-Known Member

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    whack them quite a few times before anything else, it will mushroom the head and shock the thread loose
     
    Muse likes this.
  5. brian47

    brian47 Well-Known Member

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    I'd agree with James here. There are many times when you can get away with the odd nut and bolt from Screwfix or even B&Q. You might even find what you're looking for in what my father used to call his "Joy box"*.
    But there are times when only the best is good enough, and there is only one right part, for example, brakes, steering, towbars, cylinder head and so on. There are no doubt other places and fittings which can be added to the list. In other words, bite the bullet and buy the recommended parts in this case.

    *It was called his "Joy Box" because whenever he was asked if he had a part, he'd have a rummage in this big box of bits and then he'd get asked "Any joy Dave?"
     
    Muse likes this.
  6. Muse

    Muse Member

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    Thanks for that Brian, good old joy box haha.
    I've purchased the original parts, I'll try whacking it more with a hammer and see if I can file it down to fit my extractor. If this doesn't work I'll try a hammer and chisel. Replacing the discs and brake is the easy bit, it's removing the bloody bolts!
     
  7. Brown

    Brown Well-Known Member

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    A lot of folks on here swear by those Irwin bolt grip sockets for caliper removal. An imperial 1/2" socket is a slightly tighter fit than the equivalent metric one and might be helpful if you have one to hand.
     
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  8. Muse

    Muse Member

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    Thanks! I have the Irwin extractors, they're great. however, two of the double hex retaining bolts have completely rounded... I had to file it smaller to fit socket due to being between two sizes. The socket just keeps slipping despite a massive grip to begin with.... any advice please? I've soaked them in special Penetrating type of WD40 and whacked many times with a hammer.

    Feel like I've wasted 3 hours!! :(
     
  9. neilly

    neilly Well-Known Member

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    Can you get an impact wrench ( if you have one ) on it with the irwin sockets?

    Cheers
     
  10. Flossie

    Flossie Well-Known Member

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    1/2" multipoint socket fits real snug or the same in ring spanner.
    Edit to say- sorry! Wrong vehicle:oops:
    Edit edit...19mm? Heads?Or thread diameter?
     
    Last edited: Jan 10, 2017
  11. Muse

    Muse Member

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    Thanks for all the advise! Managed to get two calipers off and changed the discs and brakes!
    My method using all of your comments to guide me, because when I used a box wrench with hardly any force the ribs completely rounded off.

    1. Wire brush all the crap off the bolt
    2. SOAK in pen oil or WD40
    3. WHACK with a hammer hard many times
    4. To make the bolt fit an IRWIN Bolt Extractor, I used a file (dremel) to give the bolt some edges and small enough to go into the socket.
    5. Keep trying the socket for a decent fit, then hammer into place until fairly tight and deep.
    6. SLOWLY begin to remove the bolt, if the extractor starts to wobble as its spinning, remove ratchet and replace in another position.
    7. It will eventually come off once the socket bites.

    Wow... they're amazing tools. Along with the impact screw driver to remove the disc screw.

    [​IMG]
     
  12. neilly

    neilly Well-Known Member

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    Yep,

    Technically , they are MULLERED.... :p:p:p:p.......nice job getting them off.

    Cheers
     
  13. Muse

    Muse Member

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    Mullered=Extremely Drunk? I feel like it after loosing my temper all night until I figured a feasible method out of removing the ba$t@rds haha.
    The car was going to the scrap yard earlier on! :mad::mad: :rolleyes:
     
    neilly likes this.
  14. meego

    meego Well-Known Member

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    Sounds like you only have a half set of the Irwins.
     
  15. Muse

    Muse Member

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    Got the full set mate. However mine were so badly corroded that it actually just slides when I used the correct socket. Had to quickly dremel down to the lower socket.
     
  16. freelance

    freelance Well-Known Member

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    Complete set is fourteen I believe
     
  17. gstuart

    gstuart D3 Grandad

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    have got both irwin sets

    theres 10 x in there,

    maybe there's another set

    IMG_0141.JPG
     
  18. gstuart

    gstuart D3 Grandad

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    u deserve a bottle after getting them out

    have before now when all else has failed in putting some stilsons on a bolt , never fails, lol
     
  19. freelance

    freelance Well-Known Member

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    Yes another set with four in, for larger heads, up to 24 mm from memory
     
  20. meego

    meego Well-Known Member

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    Usually if one is spinning on the head, the next one down fits it. That's why I thought you only had the half set. No worries. You got them off which is the important thing. A Dremel is high on my to buy list.