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Star screws not moving

2K views 24 replies 12 participants last post by  Neil F. 
#1 ·
Even though I'm using the right size star bit, I am afraid that they are going to strip out before they ever move. Aside from using a lubricant such as WD-40 or Zep preserve, can anyone recommend on how to get these bolts out without damaging the head?
 

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#3 ·
I twisted the business end of a torx key trying to loosen the bolts attaching the shoulder harness loop to the sport bars in the back. Evidently, it was not hardened. Choose a good quality bit to fit your 3/8 ratchet, hardened properly, and use a breaker bar. It will come loose as long as the torx socket has not been buggered up too badly. I learned my lesson with the cheap ones. Only use the cheap ones for smaller screws that don't need much torque, like the ones used to hold plastic pieces in place.
 
#4 ·
Oh, and if the torx socket in the head of the screw has been damaged at all, replace the bolt with a new one. You may not get it out twice otherwise.
 
#6 · (Edited)
Those Torx-head bolts are tight and hard to remove because their threads were coated with Locktite when the factory installed them. Even a new high quality Torx bit can be snapped by using the wrong technique or too much force like from an impact wrench set to too high of a torque setting.

However, they can be made to be fairly easily removed if you can get enough heat through the bolt down to the threads which will soften the Locktite. Inserting a Torx adapter bit into the bolt head and then heating the adapter with a gas or propane torch, or a heat gun so the heat would work its way down through the bolt to the threads would be my preferred method.
 
#8 ·
If you are going to use a impact be sure to use a HAND IMPACT
 
#9 ·
Use a drift pin and a drilling hammer give it a good whack if it won't budge with a wrench or impact use some heat directed at the bolt head once it cools ( warm to the touch) wrench it. Assembly locktight is wicking grade. Meaning you have to hit it before applying torque.
 
#11 ·
Loctite® 290 Wicking Grade Threadlocker
A medium-strength threadlocker for pre-assembled bolts up to 0.5" (12 mm). Penetrates threads by capillary action. Secures set screws and other assemblies after setting are completed. Seals welds and porous metal parts. Protects threads from rust and corrosion. Localized heating and hand tools are needed for disassembly.
 
#22 ·
put the torx bit on your 3/8th ratchet and apply contant pressure as a buddy continusouly wackes the socket with a hammer. unless you have an imact drill/hammer like others suggested

i did this saturday to get my breakline screw off. its torx bit andwas rusted shut, we heated it first too. after trying othe rmethods for like 20 mins. it came right off when we did this
 
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