Stripped Hex screw(s)... HELP!

[talentsearch301]

Okay I was trying to change the diff and I had 2 stripped hex screws.

What can I do?

I bought a new set of allen wrenches but working with alloy parts some of those screws have a bite to them and cant get them out.

Any sugesstions?

Theres got to be a way...
This cant be the end!

H
E
L
P

[myrxseven]

Easiest and most effective way would be to dremel a horizontal or vertical(doesnt matter which one) groove into the head of the screw for removal with a flathead screwdriver.

[sheetmetal2]

What he said but don't to scared if you get the part a little with the dremmel. Not a big deal. If you are using the quality hex wrenchs make sure that the hex socket is completely clean of all dirt. That seems to be the culprit every time.

[talentsearch301]

thanks guys!

[zrcman]

If the screw has Loctite on it you may need to apply a little heat. The tip of a soldering iron will help.

[kmh]

I have found it best to invest in a screw extractor set. The dremel idea works pretty good but, sometimes the diameter of the cutting disc causes you to cut beyond the screw head leaving cut lines in the area around the screw,i.e. the chassie, or a screw that is countersunk.

[rageworks]

Get yourself a cheap set of the smaller Torx (star shaped)
driver bits. Pick one that is just a hair bigger than the
the stripped hex hole and drive it into the screw with a
small hammer. Slide your handle onto the bit and push
down on the bit as you turn the screw out.

[jozimoto]

I have found in a tight situation a pair of diagonal cutters (dikes) can get a stripped allen head screw out. Stick the point of one side in where the allen wrench goes and the other point on the outside. Give a good squeeze and spin. The points dig into the screw real good. I have used this technique many times at the track when no Dremel has been available.