Tranny Bolt Nightmare

[stupidslow02gt]

I have 3650 and I am trying to take it out to put in a clutch. I have every single bolt out except for one on the top that is completely rounded. I mean it is like shiny smooth now its so bad.... We have tried everything, we went down to sears and bought a set of "bolt-out" bolt removers (they were terrbile and I think even destroyed the bolt further) We have put an impact on it, 1/2 inch breaker..... It just wont budge and now that it is round I am just completely stuck.


I mean we are to the point of considering pulling the motor or cutting a whole in the floor board to get to the bolt..... At this point I dont even care if we break that ear off the bell housing, I would rather replace that then pull the motor. Today my buddy is comming by with an air impact hammer with some chisle and pointed bits; we are just going to try and destroy the head of the bolt to at least get the tranny out.


Can any of you offer me any better advice on what I can do?

 

[snowb07]

I had the same trouble. I removed the lower intake and put a wrench on it and I was able to get it off.
another thing you might run into is getting new bolts to replace to ones you rounded. ford does not sell the direct fit ones anymore and you will have to go a size longer and a higher grade.

 

[BCB00GT]

I always recommend taking the top bolts out first. If all other bolts are removed and the engine is tilted, the tranny will want to tilt more on the top bolts making it even harder to remove them. Too late now but may help someone else.

 

[stupidslow02gt]

I appreciate all of the help guys, thank you very much. I just installed comp 270's over the week and have an 03 cobra clutch ready to go in. Cams were a breeze and then I have a stupid problem like this!!!

 

[Dragstr05]

Those "bolt out" sockets have saved me plenty of times. You have to use just the right size...if you can get it on without a hammer, its too big.

Air hammer may work, but be carefull.

 

[forum155pl]

air hammer is a beautiful idea!.. i was going to say sawzall but i like your idea.. if you do end up breaking an ear off of the tranny its a bad idea to put it back up there like that.. that might put a pretty mean crack in the bellhousing when your romping on your car...

why did it round off? what kind of tools do you have?

on them top bolts you sure cant beat an impact swivel with a really long extension

when you put it back together go and get your self a ratcheting wrench and hit the 2 top bolts from the engine bay.. thats another good way to take care of em.

best of luck man.. its ALWAYS the pita bolts that goof up on ya

 

[BennyBlown2v]

If you can just snap the bolt, then tap and pull it out when the trans is out of the way.

 

[stupidslow02gt]

Just to let everyone know I beat on that grade 8 bolt for over 7 hours with a bad ass snap on air hammer and barely bent the bolt. I flatened my chisle bit as well. I eventually had to hit the ear of the tranny with the hammer from the top. Had to break the ear off around the bolt in order to get the tranny out. Once the tranny was out I backed the bolt out by hand...... Very strange. My advice would be to work on those top two first and get the others done last. Thank you for all the help.

 

[BobHyatt]

Just to let everyone know I beat on that grade 8 bolt for over 7 hours with a bad ass snap on air hammer and barely bent the bolt. I flatened my chisle bit as well. I eventually had to hit the ear of the tranny with the hammer from the top. Had to break the ear off around the bolt in order to get the tranny out. Once the tranny was out I backed the bolt out by hand...... Very strange. My advice would be to work on those top two first and get the others done last. Thank you for all the help.

Two obvious suggestions:

(1) always undo the top two bolts first. If you loosen the rest, the weight of the tranny puts a lot of binding force on the top two bolts making them even harder to remove.

(2) throw those 12 point sockets out and use 6 pt sockets on things that are intended to be torqued tight. A 6 point socket won't round a bolt head. If you pull hard enough, either the socket will split, the ratchet handle will break, the extension will twist, or the bolt will break. But it won't round off. I bought a set of Craftsman 6pt sockets years ago (1/4, 3/8 and 1/2 in dirves) and use nothing else unless forced to (some bolts need an 8 pt, 12 pt, or on a mercury outboard connecting rod bolt a 16 pt socket is needed). Far easier to find the right tool, rather than using the wrong one and getting into this kind of problem...