Rounded Torx Bolt - How to get it out!

My mechanic failed to install my EGR blank correctly, instead fit the blanking plate to the metal pipe coming off the manifold, not to the manifold itself.

I didn't notice till I felt a drop in power, the pipe has split. For the time being I have managed to bodge it so the car runs.

Problem is the two Torx bolts have rounded completely. So far I have tried

- Hammering a larger Torx bit in
- Hammering an Allen Key in
- Hammering a Torx socket over the top - Cheese inside tough outside!
- Epoxying an Allen Key in
- Mole Grips

Not enough space to get a drill without taking the rad off & intercooler off. I'd rather not.

any other ideas?

Irwins ...

Irwin Bolt Grip Remover 5PC Base set 394001: Amazon.co.uk: DIY & Tools

Dippypud said:

Irwins ...

Irwin Bolt Grip Remover 5PC Base set 394001: Amazon.co.uk: DIY & Tools

Click to expand...

to big dippy,same has happened to my td5.

could you not weld a nut to it

andrewblueboy said:

could you not weld a nut to it

Click to expand...

not enough room bud.

never mind that. wot ya done with your hazard switch

gemsdad said:

to big dippy,same has happened to my td5.

Click to expand...

Feck !!!

they go up to 3/4"

Dippypud said:

Feck !!!

they go up to 3/4"

Click to expand...

nooooo,the sockets are to big for the bolt head.

gemsdad said:

nooooo,the sockets are to big for the bolt head.

Click to expand...

:doh: doh, silly me -

They start at 5/16" or 8mm

What size is the head on your TD5?

Dippypud said:

:doh: doh, silly me -

They start at 5/16" or 8mm

What size is the head on your TD5?

Click to expand...

dont knowbut that small socket looks to big.i will check it tomorrow.

cold chisel?

flat said:

cold chisel?

Click to expand...

tried it,just shears the metal of the round head.

sounds bad
You could try removeing the manifold put in a vice and weld ( as some one said) something to it, the heat will help shift it

gemsdad said:

tried it,just shears the metal of the round head.

Click to expand...

oh rubbish

its either going to be manifold off then or radiatior/intercool out i reckon and extract it on a bench

If it was me,i would take it back to "my mechanic" and ask/tell him to put it right!

flat said:

oh rubbish

its either going to be manifold off then or radiatior/intercool out i reckon and extract it on a bench

Click to expand...

if i cannot get the pipe off,i will cut the pipe and use an ally plug in the pipe,well sealed of course.

I rang him, no answer. Sent a text so he should get back to me soon.

Kinda ****ed off though because I was going to do it myself, and would have done it right, just through it in with a few other bits to save me time.


Bought those Irwin's hopefully they should do the trick.

bankz5152 said:

I rang him, no answer. Sent a text so he should get back to me soon.

Kinda ****ed off though because I was going to do it myself, and would have done it right, just through it in with a few other bits to save me time.


Bought those Irwin's hopefully they should do the trick.

Click to expand...

the top bolt you should be able to get at,the lower one might be a problem.good luch though,let us know how you get on.

Well I was thinking if I get the top one off I should be able to 'break the seal' on the bottom one making it easier to get out.

I shall, will be having a crack on Friday.

which bolt do you mean allen bolts to ex manifold or inlet