Stripped bolt head Dana 20

[casadejohnson]

Sometime since 1966 the cap/bolt for one of the detent springs and ball was rounded off on my dana 20. I need to get it apart so I tried welding a nut to it but its not going to plan. I weld it on and let it cool but when I put a wrench on it, the nut just twists off. obviously, the weld is not penetrating the stripped bolt head. Not sure why the weld's not sticking but I really need this out so I can pull this thing apart. Any ideas?

 

[bax]

First see if you can drive a six point socket on it. if not cut a slot in the bolt head for a big impact screwdriver. heat the case around the bolt. Don't heat the bolt. Wack it a few times and it will come out.

 

[casadejohnson]

First see if you can drive a six point socket on it. if not cut a slot in the bolt head for a big impact screwdriver. heat the case around the bolt. Don't heat the bolt. Wack it a few times and it will come out.

I tried the six point socket but the problem with these bolts is that the bolt head is really shallow so it does not have a lot of meat on it to get the socket on. I'll have to try cutting a slot in it.

 

[bigjhoov]

Are you cleaning the bolt head before trying to weld on it? Every D20 I've worked on is covered in about 10 layers of oil. Might make a difference.

 

[casadejohnson]

Bax,

Thanks for the advice. A slot cut into it worked great with the impact driver. I screwed around with this thing for an hour and a half trying to weld on nuts. Tried it your way and it was off in 5 minutes.

Does anyone sell those goofy detent spring bolts? I can reuse this one if I have to but a replacement would be a better choice if I can get one.

 

[Viperwolf1]

JBG might have them. I'm sure Don Allison has a couple hundred laying around too.