Question about 1988 Mercedes-Benz 300

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What the best way to remove seized head bolts

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First try bashing the bolt head straight downwards. This may loosen the corrosion in the threads. Take care not to hit surrounding structures.

Next try a large impact wrench (you can hire them) with a high strength socket which is a good fit. Take care the wrench is set to run in the undo direction.

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Posted on Apr 21, 2015

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First, is the head off or is the bolt easily reachable? Your problem is common. The bits may be snapping because you are either pressing too hard or are changing angle while drill is in motion. The best thing you can do is first make a bit guide...Take a piece of steel at least 1/4" thick that is long enough to reach two adjacent bolts (use manifold as a template) drill both holes to the size of the studs. The one for the broken bolt should be substantially smaller and centered over the broken stud. Drill first with a bit of the same size you used to make the pilot hole. then go up to a size just slightly smaller than the stud, so threads are not damaged. I like using a reverse twist bit for this because the drill force and heat caused by drilling will often back the stud out. But those bits are hard to find. after the hole has been drilled, use a straight type thread remover (not an "easy out" ...they spread the stud and exert force against the threads actually making removal harder) straight type removers look a lot like torks bits and are tapped into place creating grooves that help turn the stud. you can apply some heat to the area, but generally just turn the stud out slowly, use lots of solvent and after each turn out, run it back in to clean the threads and prevent binding. Funny...It takes longer to write this than it does to actually do it!!! When replacing, put anti-seize compound on the new stud.
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