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Discussion Starter · #1 ·
Have a Kolher K321 that the PO used an allen head bolt on the exhaust and stripped the inside out during installation. I have tried using both Metric and "normal" sized allen wrenches to see fi I couls get something to bite and get the thing out but had no luck. I have also tried both shannel lock and slip joint pliers on the outside of the head along with soaking with PB blaster every couple days for a the past week with no luck. I have considered taking either a hacksaw blade or dremel tool to slot the head and use a screw driver to maybe get it out but wanted to check to see if there might be a better way. I have removed the gasket and the exhaust is free to move, just can't get the bolt out.
 

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Galen, if the head of the bolt is above the surface of the metal, I've had good luck placing a nut on top and welding it down through the center. I've removed many rounded off bolts this way. If you don't weld, maybe you could find someone locally that could do that for you. I'm sure it wouldn't cost much.
 

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Try using a Torx head socket, not hand driver. Usually you can find a torx that will drive into a damaged allen socket. Drive it in with a hammer, and then rap it sharply a few times to help loosen the rust grip. If you have an air hammer, that works well. Then, try to unscrew it. Again, air tools work much better than hand, impact wrench should get it, if the torx gets a good bite.
 

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I had this problem with the engine I put in my tractor. I had to use a little heat in order to break the thread free from the head. It did take a while but the last thing you want to do is break the bolt off flush with the head. You think you are having a PITA time now then just wait until that happens
 

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Discussion Starter · #8 ·
Thanks to all that replied, I got the thing out using the Torx head socket and some heat with the torch. If that didn't work I was going to go the welded nut route but I was able to work it out with the first approach.

Galen
 

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If you can get a Torx, larger allen or ez out to bite a hand held impact driver sometimes works for me. It is the type that you hit with a hammer. If the bolt breaks flush you can always go to plan B. The exhaust port on most K series are threaded on the inside so you can usually fashion an exhaust off of that. Gregg
 
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