09phazermichagan
Expert
I was changing my oil last night and was useing a craftsman allen (the kind with the rounded/ball tip on the long end) to remove the plug in the motor and.... SNAP 
the end of the allen broke off flush with the head of the bolt 
so now the end of my allen is stuck in the head of this bolt. what should i do? vice grips wont work already tried.
the end of the allen broke off flush with the head of the bolt so now the end of my allen is stuck in the head of this bolt. what should i do? vice grips wont work already tried.
APEX 06
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Go get a set of EZ outs. You get them at sears
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Maby try taping on it with a screwdriver and hammer in the opposite direction that it broke and it should fall out.
YammyRX1
TY 4 Stroke Master
Try Krazy gluing the broken pieces together to see if it will pull the ball out or go at it with a Dremel and diamond bit.
RayKnobs
Expert
It it break out flush or do you have at least a nub to grab?
Jeremy
Expert
Magnet, mig weld a tack on it and it should pull out, , jb weld, yammiRX1 said crazy glue, what ever you use to remove it just remember that you should always use a non rounded allen key if you can get at it nice and straight like this bolt !!! Lesson learned the hard way !!! good luck buddy !!!
09phazermichagan
Expert
ok i got it loose but not out its like this thing is teaseing me lol i can rattle the pice around inside of the head of the bolt but it wont fall out i bet if i rode it some the heat and vibration would shake it out. i thik last time i used a 3/8 drive allen so i paid the price for being lazy this time
yam177
TY 4 Stroke Master
09phazermichagan said:ok i got it loose but not out its like this thing is teaseing me lol i can rattle the pice around inside of the head of the bolt but it wont fall out i bet if i rode it some the heat and vibration would shake it out. i thik last time i used a 3/8 drive allen so i paid the price for being lazy this time
Once those snap in they are stuck!!! Use a chizl and hammer get the bolts out and replace the drain plug
YammyRX1
TY 4 Stroke Master
You could try a small masonary drill bit (carbide tip) to see if you can get a hole in it and then use an easy out.
biffdotorg
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The same think happened to me on the windshield mount. Snapped one of those round-head craftsman allen wrenches right off. At least it was the first one I tried.
My dealer delivered my new Phazer with the mount installed upside down on the riser block. Not only does it leave a gap between the headlight and the shield, it leaves the crossbar on top, so I cannot install a factory windshield bag.
My dealer denies that this is the case, but I have pics of me taking delivery with a huge smile on my face! They should be the jokers trying to get that sucker out of there. It's almost impossible without a welder.
My dealer delivered my new Phazer with the mount installed upside down on the riser block. Not only does it leave a gap between the headlight and the shield, it leaves the crossbar on top, so I cannot install a factory windshield bag.
My dealer denies that this is the case, but I have pics of me taking delivery with a huge smile on my face! They should be the jokers trying to get that sucker out of there. It's almost impossible without a welder.
darens
Veteran
Welding it is by far the easiest and quickest, providing you have a welder. Most other options will have you cussing more than anything!
09phazermichagan
Expert
so could i just grind the head of the bolt off? would the bolt come loose? I dont want to hammer on the bolt i'm worried i might crack the oil pan.
Crewchief47
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You could try grinding a slot in the head with a dremel and use a nice large flat screwdriver with a wrench-able shaft....
I vote for removing plug with chisel/sharp punch and hammer als
therwise try using a 1/2" drillbit right into the allen bolt hole.What you are trying to do is cut the small lip that is keeping the ballend in there.You might have to grind of the very tip off the drill go in until it hits the ball.Then use a Pick and magnet to get it out.Diegrinder would work also.There should still be enough of allen hole left to remove it with a good sharp straight allen key.I feel your pain buddy.Hang in there.Call it names.Usually makes a guy feel better!
therwise try using a 1/2" drillbit right into the allen bolt hole.What you are trying to do is cut the small lip that is keeping the ballend in there.You might have to grind of the very tip off the drill go in until it hits the ball.Then use a Pick and magnet to get it out.Diegrinder would work also.There should still be enough of allen hole left to remove it with a good sharp straight allen key.I feel your pain buddy.Hang in there.Call it names.Usually makes a guy feel better!09phazermichagan
Expert
so happy i could cry beers on me!!!! I got it out i had to drill about half way into the bolt head then got is out with a pic and small hammer. never will a ball end allen touch my babby again thanks guys. btw got lots of oil out of the pan 1/3 quart maybe
beers on me!!!! I got it out i had to drill about half way into the bolt head then got is out with a pic and small hammer. never will a ball end allen touch my babby again thanks guys. btw got lots of oil out of the pan 1/3 quart maybe
