How to remove rounded brake disc retaining screw

[Conanius]

Hi All,

Tried to do the front discs on my e46 330 yesterday, and the discs are held in place by a flush allen screw.

To say it is rounded, doesn't give a true description of how bad it is. it looks like someone did it up with an air gun and kept tightening till all the head was smooth.

Me and NickXX spent the best part of 3 hours trying everything we could think to get it out (impact wrench, hammering in an allen head, using a metal punch to try and spin the bolt, etc) but nothing.

Is my last option to try and drill it out?

 

[jh30uk]

Drill hole and use an easyout.

 

[Conanius]

link me up ?

 

[jh30uk]

Well from my use as engineer at work for 20years but 1min :

Heat may help also.

 

[jh30uk]

DP

 

[ianh]

If you haven't got access to any easyouts just use the right size drill-bit (same diameter as hex hole) and it'll only take the head off just leaving a stump sticking out which you can get molegrips on, as I had to do on my old 740.

 

[Maccapacca]

Drill it out and there should be enough to get a pair of good mole grips on it.

 

[Iamzod]

I had the same problem on an engine I've got, if you have any access to any welding gear you could get a small piece of copper, drill a hole in it slightly smaller than the head of the allen key bolt & then place it over it & weld a big blob of metal to it.

Get mole grips on metal blob and remove.

 

[Lopéz]

Drill it out and forget it ever existed, the wheel bolts hold the disc in place anyway,

 

[hyperseven]

On my RC stuff, usually JB Weld an old allen key in.

 

[Alibaba99]

Drill it out and forget it ever existed, the wheel bolts hold the disc in place anyway,

The retaining bolts prevent the disk from coming loose when a wheel is removed, which prevents grit and dirt from from getting between the disk and hub which can cause issues.

 

[Iceman]

Drill it out and forget it ever existed, the wheel bolts hold the disc in place anyway,

Done this many of times. Best way really.

 

[Conanius]

Ok thanks for the replies... When you say ' drill it out' can I be clear in what I think you are suggesting...

Do you mean, do an initial central pilot hole
Go up a drill size, widen...
Rinse and repeat until the head falls off the screw and the disc comes loose

Right?

 

[snapdragon69]

Just drill about 6-8mm drill to take the screw head off and the disc will come off, the stub is then usually loose, but if not, use molegrips to unscrew as already said.

 

[Lopéz]

The retaining bolts prevent the disk from coming loose when a wheel is removed, which prevents grit and dirt from from getting between the disk and hub which can cause issues.

If the disc has been on any longer than a few hundred miles it generally won't fall off when you remove the wheel. How is dirt and grit going to get in there anyway unless there is a mini tornado whipping it up from ground level?

 

[Iceman]

Ok thanks for the replies... When you say ' drill it out' can I be clear in what I think you are suggesting...

Do you mean, do an initial central pilot hole
Go up a drill size, widen...
Rinse and repeat until the head falls off the screw and the disc comes loose

Right?

Yeah thats spot on just drill it till the head falls off. You can try and get the rest out if you want but chances are it'll be seized solid.

 

[rodenal]

As above, drill it out and forget about it.

If you really, really want to get it out cut a slot in it with a dremel then use an impact driver to turn it - wouldn't bother though

 

[pepsilol]

Hammer in a torx. Always works for me .

 

[rodenal]

Oh, on the e46 - depending how long that disc has been on there don't be too surprised if the bearing comes out with it - new hub time if so

Edit - no I think I'm being stupid, I would have had the hub nut off hence why it all came free

 

[Clarkey]

Use an extractor, out in 2 mins flat no problem.