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Stuck screw in clutch cover

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McCabe-Thiele (Ted):

--- Quote from: alexdecker on February 08, 2022, 01:03:56 PM ---Hand tools. A manuel impact screwdriver of this type: https://www.walmart.com/ip/Premium-Impact-Driver-Set-Manual-Reversible-Impact-Screwdriver-Kit-with-Metal-Case-14Pcs-Set-Screwdriver/838895016

--- End quote ---

Back in the 1960's when I worked on my Honda 250 Dream I always ended up with one or two that would not budge - I used to drill out the screw head then with the cover off use a stud remover. Even that could be problematic as then the casing was often stuck to the bolts.

I wonder if a freezing cycle like plumbers use on water pipes might help?

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alexdecker:
But when you drill it out, so you just put a metal drill directly through the screw, and then that's it? I can't picture how that is helping?

McCabe-Thiele (Ted):

--- Quote from: alexdecker on February 08, 2022, 01:23:52 PM ---But when you drill it out, so you just put a metal drill directly through the screw, and then that's it? I can't picture how that is helping?

--- End quote ---

I used to use an oversized drill or even a countersink bit so you are just drilling off the screw head leaving the scew shaft intact.

Something that can work is putting back the screws adjacent to the stuck one and tightening them up again - then try your manual impact tool again - I have found cordless impact tools much more effective than the manual ones due to the way they apply the turning force with the impact so quickly and repeatedly without coming out of the JIS head.

philward:
Can you get all the other screws out Alex? If so, if you drill the head off the 'stuck' screw, you can then withdraw the case leaving a (headless screw). I use a cone shaped rotory bear in the cross of the screw head to take the edges off before starting to drill - to prevent the drill catching. Then start with a 3mm drill going upto 6.5mm/7mm - drill carefully and the head of the screw should come off.
The next stage of the process is obviously to remove the remaining headless screw. When applying a grip such as stilsons (grip better than molegrips), quite often the force applied from one side (ie, the lever of the stilsons) twists the stud and will shear the stud - so if you can get 2 stitsons and apply at 180 degrees, you will have equal force applied to the stud which will minimimise the chance of shearing - it may still shear.
If it shears, the next stage would be to cut the stud flush with the crankcase (carefully so as not to mark the mating surface), and drill out he screw from the crankcase/and/or helicoil - but lets take one step at a time!

alexdecker:
I finally got it out! By drilling it out. Fortunately it was the only one (on the clutch cover - knock on wood). Haven't gotten to battle with the vice grips its, but doing to in a 180 format is good advice! Thank you! Hopefully it will come out rather pain free …

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