What’s the trick to remove these 6mm Allen bolts?

[dgbeatty]

ThIs is the tool of choice. Incredibly tough, just don't abuse it. Mine is nearly 50 years old and still in good condition, always reserved for difficult task.

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Schau in das Buch

[4Gears4Tires]

I have a similar tool. Mine doesn't fit in there.
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition

[zoti]

Ok. Nothing works. The bolts are stripping. I need extreme measures.

One stud of the water pump came out with the nut. The other 2 are preventing me from pulling the pump out with the bypass hose.

I need to get this old pump out.

[dabaron]

here is how i approached the same issue;

clamp J hose from 3/4 head to bleeder ring, clamp pressure tank to bleeder ring hose.
remove both hoses from bleeder ring
jack rear of bus up 22".
lower engine enough to expose pulley, support on cribbing.
WATCH 1/2 hose going to tower and bleeder hose to the thermostat housing!!!! you should be able to lower it without removing them, but you might clamp them and remove just in case.
use impact gun to remove pulley bolt.
use pulley puller to remove pulley.
remove the water pump pulley.

you now have access to the water pump, the cross over pipe, and the high pressure oil sender.

also works if the pulley seal leaks :/

do the needful and slap it all back together.

this takes far less time than you think and gives you good access with normal tools. esp. if you round the allens out.
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1991 Vanagon GL Camper
i had no idea i wanted to be a mechanic
"burnin oil and cookin coils" -- Destructo

BiWerks Design, LLC

[zoti]

[dabaron]

[zoti]

[dabaron]

[whip618]

what works best for me is to use a series of 3/8 drive extensions and go in through the the license plate door where the coolant overflow tank lives, it may sound crazy but it works. as far as the stripped allen bolts I have used a shortened easy-out to grip the ID of the Allen hole in the bolt head.

Phil
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Life is simple....either you're qualified or you're not.
USSVI.......Pride Runs Deep
USSVI Life member and Holland Club member

Samba Member No. 3307

[zoti]

[lcolon]

I use a bit driver ratchet. I have a few different ratchets in small sizes. You can then use a 6mm "bit" that slots into the ratchet and it fits in behind the pulley. My wife got me a small ratchet set with bits from MAC Tools and I keep it in the van at all times.

You can also buy these off amazon. I would get a high quality one that has many splines. This one is fairly "short" (I have this exact one and use it for a number tight spots on cars) You can get longer ones from pro tool places like MAC that give additional leverage.

https://www.amazon.com/Wera-Square-Drive-Ratchet-T...amp;sr=8-3
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1984 Vanagon Westfalia - Vanna
1971 VW Beetle

[4Gears4Tires]

Ah, yes! That's genius. I've had my eye on this set for awhile. I really like Wera tools. This one comes with the rachet and bits. Just ordered it. I'll post pics if it fits.

https://www.amazon.com/Wera-056490-Tool-Check-Ratc...&psc=1
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'87 Syncro
Ferric Oxyhydroxide Superleggera Edition

[lcolon]

This is the exact one I use for getting back there... It came with a kit with several bits and an extension:

https://www.mactools.com/en-us/Screwdrivers-and-Bi...it-Ratchet

The wera one is nice as well... the Mac one is a little longer for more leverage.
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1984 Vanagon Westfalia - Vanna
1971 VW Beetle

[jberger]

https://chapmanmfg.com/products/1000-mity-master-set

This is the ratcheting bit set I use. All ground bit faces.. nice family company too.

For the water pump, I always just commit to pulling the crank pulley. If you don't have the tools to accomplish that I understand but for me it's a must. Pull the Cat and Muffler, heat shield and expansion tank then work in comfort. Really doesn't take that long.

J

[Alan Brase]

I use a 6mm Allen 3/8 drive socket. Get a quality brand. Snap-on, Mac, SK, Blackhawk. Possibly European brands. This is one place you cannot afford a failure. The same tool REMOVES CV bolts. Never replaces them tho. I use 12 points.
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Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home

[Alan Brase]

I know it seems like the job from hell. After doing it about a dozen times, it's not so bad.
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Al Brase
Projects: 67 sunroof bug, 67 Porsche 912 Targa, 70 Westy
Dec 1955 Single Cab pickup WANT 15" BUS RIMS dated 8/55, thru 12/55
To New owners: 1969 doublecab, 1971 Dormobile
Vanagons:
80 P27 Westy JUL 1979, 3rd oldest known US
83 1.6TD Vanagon, 87 Wolfie Westy daily driver, swap meet home

[Merian]

[zoti]

I tried heat with a small torch. Can’t get it hot enough.

I tried a chisel and a hammer. Won’t budge.

Any 6mm tool I manage to get in there just rounds the inside.

So,

Any advise on how to cut the bolts off? I’m tired of those sobs.

[Vanagon Nut]

If you have access, use hand held impact type tool and a reverse bit that would bite into allen head?

As a last resort.....

Drill hole cross wise in bolt head, use a strong pin (stainless?) through that?

Neil.
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1981 Westy DIY 15º ABA

1988 West DIY 50º ABA

VE7TBN

[jberger]