Replacing CV Boots

[Maxwe11]

I am currently having a bit of a struggle removing the old (possibly original) CV boots on my '89 DG. I have attempted to get the bolts out but due to corrosion the Allen key bolts have totally lost their shape. I have tried attaching mole grips and removing with them to no success. I think my options are as follows:
A) Drill into each bolt head and then using a bolt extractor carefully removed them
B) lop the bolt head off and get the boot out the way then attempt the above with less in the way but risk getting metal filings in the CV joint.
Any other options or advice would be greatly appreciated!
Thanks in advance,
Max

[cobblers]

Hammer a 12 sided socket over them, or use some better mole grips. Only start drilling as an absolute last resort - In the past 20 years I've done dozens and dozens of these and I've never had to get a drill out - the bolts have always come out another way!



If you do drill the heads off you'll be able to slide the CV joint off the remaining stud, then just unwind it from the drive flange by hand - they're very unlikely to have seized on the threads.

[muttleypup]

Have you cleaned out all the crud from the bolt heads, degreaser and a thin screwdriver or even a needle. The allen key may not be seating far enough in the head. Also possible that theyre torx heads, easy to miss under the van with poor light and crud in them

[TwinTurbo]

Have you tried heat? 

I have not done one in a long time but I had an impact driver in the tool box ( the type you hit with a lump hammer ) and that used to free them off. 

Rob

[crazyhorse]

As noted above

https://m.youtube.com/watch?v=jh5Fvw2fr3I

This worked for me…

[silverbullet]

Use a decent quality 12 point bit and hammer it into the spoiled hex hole with a copper mallet. Wear eye protection, cheap bits can shatter. This usually works, replace with nice new 12 point bolts etc from Brickie.

[Cecil]

Angle grind a well placed flat on the bolt head for one jaw of the mole grips to grip on might work though metal particles will be flying everywhere.

Beware new gaiters may not last very long compared to originals.
 

[Dueller]

also use an Irwin set with a hammer

Ive something similar i got from Machine Mart one cheery Sunday, they are a spiral flute that tightens down and onto the head regardless of shape etc

Ebay title Damaged Impact Screw Removal 14PCS Bolt Nut Extractor Twist Socket Tool Kit Set
£15.98

[dazzerT251900td]

Hi there.
Ive used a lump hammer and sharp chisel before on the edge anti clock wise hit should shock it moving.
good luck.Dazzer.