Method to Remove Rusty Rounded Caliper Bolts

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Muse

Muse

Member
Posts
26
Location
Cumbria
Hey! I'm looking to buy x4 front caliper retaining bolts for my Disco II. I believe this is them:
http://www.paddockspares.com/ftc2996-bolt-caliper.html

They're 19mm double hex part number: FTC2996 Horrible things to remove... I've completely rounded the rusty old ones and now they're stuck... haha. Is there a cheaper bolt to use which isn't a double hex? £17 for 4 is pretty steep... Thanks!
---------------------------------------------------------------------------------------------------------
EDIT>>
Thanks for all the advise! Managed to get two calipers off and changed the discs and brakes!
My method using all of your comments to guide me, because when I used a box wrench with hardly any force the ribs completely rounded off.

1. Wire brush all the crap off the bolt
2. SOAK in pen oil or WD40
3. WHACK with a hammer hard many times
4. To make the bolt fit an IRWIN Bolt Extractor, I used a file (dremel) to give the bolt some edges and small enough to go into the socket.
5. Keep trying the socket for a decent fit, then hammer into place until fairly tight and deep.
6. SLOWLY begin to remove the bolt, if the extractor starts to wobble as its spinning, remove ratchet and replace in another position.
7. It will eventually come off once the socket bites.

Wow... they're amazing tools. Along with the impact screw driver to remove the disc screw.
 
Last edited:
Muse said:
Hey! I'm looking to buy x4 front caliper retaining bolts for my Disco II. I believe this is them:
http://www.paddockspares.com/ftc2996-bolt-caliper.html

They're 19mm double hex part number: FTC2996 Horrible things to remove... I've completely rounded the rusty old ones and now they're stuck... haha. Is there a cheaper bolt to use which isn't a double hex? £17 for 4 is pretty steep...


Thanks!
Click to expand...
you need the proper bolts ,brakes are fairly important, whack the heads hard with a decent sized hammer then hammer your socket back on
 
Good point mate. I appreciate your advice on my past two posts.
As for the old one, it was so rusted, on turn of the 19mm double hex rounded it bare. I have some irwin extractor bolt sockets but its slightly too big for them, do you think I could file them smaller then try with another socket? I've been at it for 2 hours! fed up... :(
 
jamesmartin said:
you need the proper bolts ,brakes are fairly important, whack the heads hard with a decent sized hammer then hammer your socket back on
Click to expand...

I'd agree with James here. There are many times when you can get away with the odd nut and bolt from Screwfix or even B&Q. You might even find what you're looking for in what my father used to call his "Joy box"*.
But there are times when only the best is good enough, and there is only one right part, for example, brakes, steering, towbars, cylinder head and so on. There are no doubt other places and fittings which can be added to the list. In other words, bite the bullet and buy the recommended parts in this case.

*It was called his "Joy Box" because whenever he was asked if he had a part, he'd have a rummage in this big box of bits and then he'd get asked "Any joy Dave?"
 
Thanks for that Brian, good old joy box haha.
I've purchased the original parts, I'll try whacking it more with a hammer and see if I can file it down to fit my extractor. If this doesn't work I'll try a hammer and chisel. Replacing the discs and brake is the easy bit, it's removing the bloody bolts!
 
A lot of folks on here swear by those Irwin bolt grip sockets for caliper removal. An imperial 1/2" socket is a slightly tighter fit than the equivalent metric one and might be helpful if you have one to hand.
 
Thanks! I have the Irwin extractors, they're great. however, two of the double hex retaining bolts have completely rounded... I had to file it smaller to fit socket due to being between two sizes. The socket just keeps slipping despite a massive grip to begin with.... any advice please? I've soaked them in special Penetrating type of WD40 and whacked many times with a hammer.

Feel like I've wasted 3 hours!! :(
 
1/2" multipoint socket fits real snug or the same in ring spanner.
Edit to say- sorry! Wrong vehicle:oops:
Edit edit...19mm? Heads?Or thread diameter?
 
Last edited:
Thanks for all the advise! Managed to get two calipers off and changed the discs and brakes!
My method using all of your comments to guide me, because when I used a box wrench with hardly any force the ribs completely rounded off.

1. Wire brush all the crap off the bolt
2. SOAK in pen oil or WD40
3. WHACK with a hammer hard many times
4. To make the bolt fit an IRWIN Bolt Extractor, I used a file (dremel) to give the bolt some edges and small enough to go into the socket.
5. Keep trying the socket for a decent fit, then hammer into place until fairly tight and deep.
6. SLOWLY begin to remove the bolt, if the extractor starts to wobble as its spinning, remove ratchet and replace in another position.
7. It will eventually come off once the socket bites.

Wow... they're amazing tools. Along with the impact screw driver to remove the disc screw.

IMG_8785.jpg
 
neilly said:
Yep,

Technically , they are MULLERED.... :p:p:p:p.......nice job getting them off.

Cheers
Click to expand...

Mullered=Extremely Drunk? I feel like it after loosing my temper all night until I figured a feasible method out of removing the ba$t@rds haha.
The car was going to the scrap yard earlier on! :mad::mad: :rolleyes:
 
meego said:
Sounds like you only have a half set of the Irwins.
Click to expand...

Got the full set mate. However mine were so badly corroded that it actually just slides when I used the correct socket. Had to quickly dremel down to the lower socket.
 
Muse said:
Mullered=Extremely Drunk? I feel like it after loosing my temper all night until I figured a feasible method out of removing the ba$t@rds haha.
The car was going to the scrap yard earlier on! :mad::mad: :rolleyes:
Click to expand...

u deserve a bottle after getting them out

have before now when all else has failed in putting some stilsons on a bolt , never fails, lol
 
Muse said:
Got the full set mate. However mine were so badly corroded that it actually just slides when I used the correct socket. Had to quickly dremel down to the lower socket.
Click to expand...
Usually if one is spinning on the head, the next one down fits it. That's why I thought you only had the half set. No worries. You got them off which is the important thing. A Dremel is high on my to buy list.
 
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