How does one remove a rounded bolt?

Asked by Grant Nov 15, 2020 at 12:00 PM

Question type: Maintenance & Repair

I have a rounded bolt in a front brake caliper. The first
came out after some breaker bar persuasion, however, this
one tossed the socket until two corners were gone (pb
blaster had been well applied prior). I have an extractor
set, the largest socket was too small by 1 and so after a
few other attempts I used a dremel to grind the head down
to a size that would accommodate, attempting to maintain
the hex shape. Despite the extractor now fitting on snugly,
it refuses to grab and slips impotently off. I also attempted
the insert type of extractor, that broke off in the hole I
drilled for it on the first turn. Any advice?

3 Answers

103,225

tack weld a nut to the bolt head so you have something to put a socket or wrench on. Be sure to get some heat on the caliper to loosen the bolt as well.

If you can grind the head off completely and remove the caliper you will have more bolt to work with. Then you can apply heat without damaging the caliper seals.

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