Removing REALLY rusty bolts

[Subliminal]

Hey guys,

I've been doing a tranny swap on my Cummins truck. I've got everything ready to remove from my donor truck, except about 4 bolts on the crossmember.

This donor truck was an upstate NY truck, and has a nice protective layer of surface rust on everything.

This bolts have what SHOULD be an 18mm nut and a 15mm head...but they are so...weathered?..that the bolt heads all seem to fit the wrench different. Some are out of shape, some are too small for the 15, but too big for the 14. Also, really helpful is the problem area (bolt head) is on top of the frame, up by the crossmember...ie...kind of hard to get to.

Anyway, I've PB Blasted these things about 5 times in the last week, but I'm having one helluva time, and I'm looking for a better method than cutting the damned things off...because some are going to be hard to get the sawzall in...and I don't have a torch (other than my little plumber dealy).

Anyway, figured I'd come here and ask...some of you guys have to have some ideas!

Thanks

damon

 

[CATransplant]

Re: Removing REALLY rusty bolts

Consider the possibility that those bolts were changed, and US sizes used. Check out an SAE size. It just might solve your problem.

Use only 6-point sockets, preferably with an impact wrench.

Reminds me of a camper shell I bought from a guy once. It was still on his pickup, so after I paid him, we started to remove it.

Well, the guy had used like long 1/4 bolts to attach it to the rails of the pickup bed, and everything was a little rusty. So, he starts trying to unscrew the nuts off these long bolts. Squeak...squeak....squeak. Half a turn at a time.

I went to my truck, opened the toolbox and grabbed a 7/16 deep socket, a ratchet, and a 7/16 combination wrench and got in his truck bed. While he was still trying to undo the first one, I twisted off the other 7 by tightening rather than loosening.

Then, we transfered the shell to the bed of my truck and I used the bolts and nuts I had brought with me.

People are funny sometimes...

 

[Subliminal]

Re: Removing REALLY rusty bolts

Considering the truck is an 89, I guess it's very likely that they could have been changed over the years.

I should take a picture of some of the ones I've removed, though...the heads are all warped and rotted looking. Weird.

 

[JustJason]

Re: Removing REALLY rusty bolts

Can you get in there with a BFH and a sharp coal chisel and knock the heads off?

 

[Stachi]

Re: Removing REALLY rusty bolts

try a 4" grinder with a cutting wheel...cut the bolt where it projects thru the nut first , then turn the grinder and cut across the nut and bolt so that the nut is now in two pieces...smack it with a hammer and the nut halves will fall off....you can pick up an inexpensive grinder from Harbor Frieght.... once you own one , you'll wonder how you got along without one !

 

[Subliminal]

Re: Removing REALLY rusty bolts

Probably not a hammer big enough to break these grade 8 bolts that support the rear of the massive diesel and steel-cased tranny. I wish, though!

 

[jeffnick]

Re: Removing REALLY rusty bolts

I second the grinder (mine is air driven)...but first try a mixture of 50% ATF & 50% acetone instead of the PB Blaster.

 

[angus63]

Re: Removing REALLY rusty bolts

A dremel with a couple cutoff wheels, safety glasses, and a little patience makes most any fastener go away without busted knuckles and grease fires! Good luck!
For oxidized/seized threads, I've found "KROIL" to be the most effective penetrating oil. Not aware of retail locations for it, but it is available online if you search.

 

[Cofe]

Re: Removing REALLY rusty bolts

Small pipe wrench with cheater pipe.
They also make right angle pipe wrenches if you need one.

 

[Bob_VT]

Re: Removing REALLY rusty bolts

Well being in VT ..... I would not how to act if a bolt was clean and came out!!!!!

Smoke wrench cut it off OR use a propane torch and get it hot real real hot (MAPP gas works better) and when it's red hot turn it with a wench but as soon as it's loose..... turn in both ways when it starts coming out. So a half turn in for about every two turns out which keeps the threads clean.

It is VERY VERY common here and when you do any work here a propane torch or an oxy/act set is near you.

 

[barus243]

Re: Removing REALLY rusty bolts

I would look to make sure that you get the right size for the bolt heads first and foremost. Have you tried to use any penetrating oil yet? Penetrating oil left to soak for awhile will help greatly. After letting the penetrating oil soak in for about 30 minutes heat the bolts up with that little plumbers torch until they are red hot. Note: please use gloves for the steps after starting to use the torch its not fun to have writing burned into your skin. If this trick doesn't work you will have to get a bit more creative. I've had to rip off alot of those grade 8's and as a last resort (and if a socket will not fit on them) get a bar of steel and cut a hole in it that is smaller than the bolt head. Then take a welder and weld the bar to the bolt to get an even stronger way to turn the bolt head. This technique of welding will also help to super heat the bolt and it might help to break it loose. If you end up breaking a socket while working on the project then save the socket also. If the socket doesn't have a lifetime warranty where it has to be turned back in then it can be welded to a bolt head also. Its tricky with a wire welder though but you feed the wire through the opening for the drive. I hope that these suggestions help out.

 

[Bowser4x4]

Re: Removing REALLY rusty bolts

2 ideas to try....

1) Bkaster is okay, but if you can find it, try some Kano Aerokroil.... I had shock mounts on an old Corvette that would not come loose. Shot it with Kano for 2 days and while it did not pop off, it did come off.

2) There are slitting disc for 4-1/2" grinders. The blade is super thin {.045"} and will cut thru grade 8/hardend steel without a prolblem.

http://www.dewalt.com/tool-parts/ab...ed-performance-_045-metal-cutting-dw8850.aspx

Woof
Bowser

 

[HappierWet]

Re: Removing REALLY rusty bolts

14mm is .551
15mm is .590

9/16ths is .562


just a thought

 

[CATransplant]

Re: Removing REALLY rusty bolts

14mm is .551
15mm is .590

9/16ths is .562


just a thought

Yup. What are metric bolts doing on a Cummings truck in the first place? 15mm too big? 14mm too small? Where's my 9/16" six point?

 

[BF]

Re: Removing REALLY rusty bolts

ditto what's been said above... don't waste your time fussin' with them. If you have easy access to them, just cut the nuts off (from the bottom), and whack the bolts out. I have spent way too much time on prob's like this in the past... now an angle grinder and cutoff wheel comes out soon after the impact hammer, not hours later.

 

[Subliminal]

Re: Removing REALLY rusty bolts

Yup. What are metric bolts doing on a Cummings truck in the first place? 15mm too big? 14mm too small? Where's my 9/16" six point?

My oldest Chrysler car has been an 85. It was all metric as well. Chrysler has been all metric for many years.

Which is fantastic, honestly, as most Fords and GMs use a combination of Standard and Metric...which is pretty friggin annoying.

 

[rbh]

Re: Removing REALLY rusty bolts

Nothing say's ^%$T%%#^ bolt, like a good 5" zip cut wheel on the grinder.

 

[thefairlaneman]

Re: Removing REALLY rusty bolts

The pro way would be to just cut them off with a torch but a good tight 6 point socket and breaker bar will free them up fast or break them off and solve the problem. Try a strong air wrench first. Hope you have not rounded off the nuts..if so it back to the torch..

 

[Stachi]

Re: Removing REALLY rusty bolts

ditto what's been said above... don't waste your time fussin' with them. If you have easy access to them, just cut the nuts off (from the bottom), and whack the bolts out. I have spent way too much time on prob's like this in the past... now an angle grinder and cutoff wheel comes out soon after the impact hammer, not hours later.

I agree...I want to get it done NOW...not three days of soaking later...sheesh ! I work on a lot automobile exhaust systems...if it even looks rusty , I cut it off... I don't have time to soak something that I will end up replacing anyway....

 

[nofuss]

Re: Removing REALLY rusty bolts

Just an idea, out on the oil rigs we sometimes use toilet bowl cleaner on rusted bolts its the best penetrating liquid i have ever seen work. and i have seen it work on bolts so big and rusted that the impact wrench just stands up and knocks. then a guy with a bar takes them off. worth a try and only a couple minutes soaking works. 1/2 hour max.
but remember its acid so u have to be careful

P