Topic: Stuck cam cover screws

[jonclegg]

I decided to finally tackle my leaking head gasket issue with my 78' cb550. The bolts of the cam cover all came off fine, but all of the screws were stuck.

I first just PB blasted them all and tried hammering with my JIS "impacta" screwdriver. Nothing.

I decided to drill them out, I've had 100% success with my screw remover, as a side note both of the side covers needed to be drilled out. Unfortunately I broke the bit while attempting to extract one of the screws. I have the "Alden 4507P Micro Grabit Broken Bolt Extractor 4 Piece Kit", i broke the 2nd largest one. I tried using the next larger one. For some reason that bit wouldn't drill into the screws at all, I put all my dang weight on it and barely got anywhere.

I tried heating up the screws with a torch and pounding away with the JIS impacta, nothing. I sampled some of my locking plies, but none of them would really get a good purchase. I tried hammering on a 9mm bolt, but there isn't really enough clearance, to dremel a bolt out of the screw.

I dremeled one of them into a flathead, but it wouldn't come either.

I'm at wits end here, any ideas?
My JIS screwdriver http://www.levelchrome.com/Vessel-980-Megadora-Impacta-3x150-JIS-Impact-Screwdriver-_p_173.html

Video:
Stuck screws

[LesterPiglet]

Did you try the impact after you slotted the screws?

[jonclegg]

No i don't have an impact driver. Maybe that's next...

[Jerry Rxman Griffin aka MuthaF'er]

Impact driver should be your first choice for a weapon. $10 or so at Harbor Freight type places. Sears a little more.

remember, you gotta twist and apply downward pressure when you hit it. Don't expect the tool to do it. They should come loose the first pop.

[jonclegg]

Thanks, I'll pick one up tomorrow and try that. For what it's worth I thought my "Impacta JIS" screwdriver would do the same thing and it didn't work. Any ideas for a plan C if an impact driver doesn't work?

[Stilltime]

Just went through the same thing the other night.  Every bolt and screw came loose (screws I used harbor freight impact driver) except the end caps wouldn't break free for anything.  After trying several methods, I resorted to drilling the screws just enough to where they would break free, used a small sharp chisel on the edge and they spun out fine after that...

Here's a pic of the carnage.

[jonclegg]

Well, I picked up the Harbor Freight impact driver, put a torch on it for a minute to heat it up and.. nothing!. After a lot of banging I managed to bend the phillips bit on the impact driver. On order I have a the "Pro" bit Alden screw extractor, the one I had worked well until I snapped one of the bits.

Should I be using the torch for longer? It doesn't seem to get the screw very hot, for what it's worth it's just a little butane torch from Harbor Freight, I think it cost 8 bucks.

As a very last resort I can try to dermal of the heads, I'm not sure of the best attachment to use for that as those screws are really close to the metal on the cover and I don't want to damage the cover any more than I have to.

Every time I go in there I spray a bit more PB Blaster on the screws, but I don't think it's really penetrating.

[edwardmorris]

You should try and use the proper JIS impact bits. Gordon/Ilbikes here sells some outstanding JIS tools

http://forums.sohc4.net/index.php?topic=133264.0

I was able to get all my engine covers off with his standard impacta that comes with his JIS driver set. The heavy duty one in the link above is for pretty much anything that won't budge. Dremel may not work all that well so I'd recommend drilling out the head, lifting off the cover then using a vice grip plier set to twist them out.

[LesterPiglet]

A decent bit on your impact driver should remove those without a problem. I would steer clear of screw extractors.

[RRRToolSolutions]

Hi Jon, as Ed stated above - I've got the Mother of all Impact Driver Sets - the Vessel Model 2500. This is a super-duty of impact drivers and as I told Ed, be careful - you'll knock the drum out the side of the case before you hurt this thing.

I'll put these up in my store later today, but they will not be priced at the SOHC special pricing. If you want one discounted, you'll have to send me a PM or email.

$51 Delivered to your door (US) is the best I can do. That covers cost.

rrrtoolsolutions@gmail.com

Website www.rrrtoolsolutions.com

Best Regards, Gordon

[Maurice]

Before you do anything, screw the bolts back on and torque them to proper value. I.e. don't overtighten, they'll strip easily otherwise. This may remove some friction on the screws.

I faced this same issue some time ago and got lucky. See the impact driver I used, beefy and has helped me a ton since actually. The screw heads were starting to strip but even the phillips head #3 bit into them well.

Other things to try I can think of: vise grips, chisel (VERY VERY carefully, easy does it).

I have used the chisel successfully on the oil pump outer screws, and there really isn't a whole lot of clearance there... The key is patience: let the chisel bite into the screw, then hit it lightly and repeatedly in the loosening direction. No ham-fisted hits, it's not necessary and you'd break something on the cover.

Good luck.

[lucky]

Thanks, I'll pick one up tomorrow and try that. For what it's worth I thought my "Impacta JIS" screwdriver would do the same thing and it didn't work. Any ideas for a plan C if an impact driver doesn't work?

Yes...next step is to use a minature pair of needle nose style vice grips since you can easily get to it.

[lucky]

I just have to mention this.

You usually get one chance to get some screws out.
The first try is the most important.

Tap on the screw just a couple times lightly with a small ball peen hammer first before trying to loosen the screw.

THEN...
When using a hand held impact driver there is often no instructions and people never use the tool correctly.


Choose the correct bit.
It must fit properly. A #2 or #3 bit.

Then you must push down and turn the driver in the loosen position FIRST.
Then WHILE you have this torque on the screw,  strike the impact driver with the hammer.

DO NOT just place the driver on the screw and hit the driver with the hammer. That will certainly strip out the head of the screw.

[tomkimberly]

Have you tried using left hand drill bits?

If this does't work, find a shop with wire edm.

Tom

[jonclegg]

Good news, I got them out! In the end I used the Alden 8440P screw extractor with a 6amp drill, the cordless ones I had didn't apply enough torque. The method I ended up using was:

1. Use the drill end of the screw extractor to set the hole in the head.
2. Spray some PB blaster on the screw
3. Heat the screw up for a solid minute under a torch while tapping it every 15 seconds with a hammer
4. Use the extraction side of the extractor to remove the bit.

The final screw, the one that I broke the Alden 4507P Micro bit in, I couldn't drill into that one. So I used the previous method except I used the Lisle 29200 3/8" Hand Impact with a flathead I dremeled into the head. That took a bit more work, but it eventually came.

I wish I had put back the bolts I had taken off as the cover before I did this as someone recommended. The cover was coming off on one side by the time I was done, the cover won't come off like this as it has these interlocking bits on the carb side. I put back in a few of the bolts to even it out and then got the cover off.

Thanks for all the help guys, I hope this thread can be of assistance to the next guy with some really stuck screws.

Products I used:
Lisle 29200 3/8" Hand Impact Tool Set
http://www.amazon.com/gp/product/B0002NYDRG/ref=oh_details_o02_s02_i00?ie=UTF8&psc=1

BernzoMatic JT680 019110 Jumbo Flame Torch Head
http://www.amazon.com/gp/product/B00008ZA0D/ref=oh_details_o00_s00_i00?ie=UTF8&psc=1

Alden 8440P Pro Grabit Broken Bolt and Damaged Screw Extractor 4 Piece Kit
https://www.amazon.com/gp/css/order-history/ref=gno_yam_yrdrs?

Blaster 16-PB Penetrating Catalyst

Products that didn't work:
Harbor Freight Impact Screwdriver Set With Case - Bent the bits.
Harbor Freight Micro Torch - Didn't get the screw hot enough.
Alden 4507P Micro Grabit Broken Bolt Extractor 4 Piece Kit - Broke one of the bits into the screw

[PeWe]

You  must use a heavy hammer or a small sledgehammer. Too small hammer will only damage the surface of the impact driver. Impact driver must make a force inwards and twist at the same time.

It's otherwise rather easy to drill the head off, later lift the cover off and grip the screw with a strong plyer. Use a drill with same size or slightly bigger as the screw head. Drill slowly until the head fall off. I had to drill some screws many years ago. Some of them located where I was worried to crack the crank case.