T25 B*****D bolt - HELP needed please!!

[charlie_cheeze]

Hey you guys, PLEASE if you read this help me out by checking the link to the photo I took of a problem bolt on the starter motor of my 1980 T25.

http://www.flickr.com/photos/28611000@N00/3203722213/" onclick="window.open(this.href);return false;

I CANNOT get this bolt off, I'm trying to take it off so I can remove the starter motor and then bang on a new new one.

BUT have any of you seen a D shaped bolt like that before? It does twiddle 1/4 way round with my fingers, but I can't get any spanner to fix on it and it doesn't seem to shift more than a quarter turn. Is it a normal bolt? Are all T25 starters fixed on with this?

Can I use a nut splitter on it?, or would that leave me with a bigger problem?!

I just want to use my van!

THANKS FOR LOOKING AND ANY REPLIES GRATEFULLY RECEIVED

CC

[Oldiebut goodie]

A nut splitter won't do any good - it's the head of the bolt. The only way will be from t'other end worst luck.Get the plasters ready for the skinned knuckles! (At least it won't need a spanner on to stop it turning whilst you undo the nut!)
The only other way is delicate work with an angle grinder by the look of it, if there is enough room to get in there.

[charlie_cheeze]

A nut splitter won't do any good - it's the head of the bolt. The only way will be from t'other end worst luck.Get the plasters ready for the skinned knuckles! (At least it won't need a spanner on to stop it turning whilst you undo the nut!)
The only other way is delicate work with an angle grinder by the look of it, if there is enough room to get in there.

So is it possible to angle grind it off and then just buy a new bolt that will go through the hole left behind?

I can't see up there very well at all and feeling around it doesn't feel like it goes through to the other side. Does it actually go through then to a nut head? If so i guess there SHOULD be a nut head that I can get a spanner on?

I don't mind removing flesh, its the bloody bolt I want off!

CC

[reggie1andy1]

try going behind the tinware from inside the engine bay, ive changed my startermotor before and once id found that the nut on the opposite side it was really easy to do.

[jamesc76]

If you cut that off youll have really hard problems fitting the new one as the old bolt shank needs to bee removed that bolt has a 17mm head on it needs undoing from the other side!!

[charlie_cheeze]

OK cool. I'll get down and get on with the quest!

THANKS GUYS

[Mr Bean]

I can't see if you got the same van as mine - 2.1 DJ WBX - but I have a long Allen headed bolt on mine which had to be removed the way it went in by removing the nut from the other end. Like the man says you could get into trouble cutting the head off. However if that would get you out of trouble and you can't get at it with an angle grinder a 1/2" belt sander (Finger File) such as the Black and Decker power file will do it as it will reach in further. I cut belts from the wide sander belts for economy.
Good luck
Wolfie

[funbus1]

The only way to undo this bolt is from the engine bay. the foto you show with the flat bit on locks its self when you start to undo it from inside the engine bay. 2 minuet job

[jason k]

yep as your man says the nut is inside the engine bay. dont go grinding nothing!!!

its in the rhs on the back!!

dont worry this caught me out too!!!

[andisnewsyncro]

2 minuet job

Words that strike fear into the heart of any "semi - competent" VW enthusiast , or me at least

[Frostbus]

yep bolt is a throwback from the good old beetle days the d shaped head helps foul against the casting so you can tighten or undo from one side (engine side)
god i mis my beetle you could fit it in a garage and work in the warm

[Therunner]

As said above.

If it's a (standard single carb) 1.6 CT you can get to it without removing anything, if it's a 2.0 CU it may be easier if you take the air filter off.

Melvin