Belt tensioner stripped bolt

bimmaone · 08-19-2015, 12:32 AM

Hi bimmers, I'm unable to remove belt tensioner because of a stripped bolt . if you look at the picture you will notice I also messed up the torx T55 socket. The nail on the coffin, it was a brand new tensioner I was replacing

.

I was told to hammer in a smaller torx socket to tighten the bolt and unscrew it, but there is not enough clearance to do so without damaging something else when I attempted it. I will appreciate any ideas to pull this off. A new tensioner should be delivered tomorrow.

Thanks in advance for your help.

davidwarren · 08-19-2015, 06:10 AM

That looks bad. It may be easiest to just go ahead and pull the radiator and drill it out.

Wingnut335 · 08-19-2015, 06:15 AM

I think it needs to be drilled out as well. I've stripped many screw heads and this one is up there in terms of how much of the head is gone. A screw extractor won't work on this.

robthewrench · 08-19-2015, 07:16 AM

You'll need to drill it and then either hammer in another torx socket or use a really big screw extractor bit. You may have to pull out other systems to get the clearance you need.

lookalikehuuh · 08-19-2015, 07:49 AM

Before you go removing radiator and such its worth trying 2 sockets...

1. These "universal" sockets which are more like spline drives could possibly pull it out.
Example: http://www.craftsman.com/craftsman-9...7_00902496000P

2. Try a bolt extractor set. Ive had good luck with these in the past:
Example:http://www.amazon.com/Irwin-Industri...+extractor+set

Oh yea and next time make sure you are using the correct tool for the job this will prevent this exact problem.

lichtgelb · 08-19-2015, 09:16 AM

If you haven't already done so, there's only two small Torx head screws holding in the fan shroud. Pulling it out will give you a lot of clearance to work in there.

snayko · 08-19-2015, 12:14 PM

I would try pliers, socket stuffed with sandpaper etc. before drilling.
As I remember torque should not be too high to make it possible to unscrew it with just pliers

ajaye · 08-19-2015, 01:02 PM

Since you can't hammer something on as-is, there's a small possibility you can JB Weld a socket over the bolt, let it set up and remove. It may be worth a try but I wouldn't bet on it. If that fails, just get a dremel and knock the head off the bolt. Its aluminum, it will grind off very easily, once the head is gone there will be no tension and the remaining shaft will spin out by hand.

davidwarren · 08-19-2015, 01:13 PM

I take my suggestion back. I looked at it this morning and I was thinking the socket you use to relieve the belt tension was the fastener. The bolt you need to remove is in the center of the spring. That one still looks salvageable without going straight to drilling.

bimmaone · 08-20-2015, 06:58 AM

Thanks for your replies. I should have more time today after work to continue the salvage operation. I will probably remove fan shroud to give myself more room as suggested. Will keep you posted

MahiC · 08-20-2015, 09:04 AM

Hey I messed up the t 60 socket to relieve the belt tension as well. How would I go about taking the pulley off?

TheBigYahi · 08-20-2015, 10:00 AM

I'm pretty sure that the Torx socket is a T60, so that's probably why you stripped that part.

As for the bolt, you could try a bolt-out socket on a long ratchet. That's how I managed to get out a pesky OFHG screw out. This is the set I have. Not sure if the biggest size will fit the tensioner screw. You might need to hammer it on a little bit to get it to bite. I don't recommend using a drill for removing Torx bolts because you'll eventually round it off to where the bolt-out won't work.

Greyfox · 08-20-2015, 12:44 PM

If you are talking about that center bolt... get a good set of vice grips and lock onto it as tight as both your hands can squeese. Then get a big pair of channel locks and use them to turn the vice grips.

PhaseP · 08-20-2015, 01:05 PM

With fan shroud out, you should have just enough clearance to use a big heavy hammer sideways on its side face, not on its regular hitting face. Hammering in one of those extractor sockets mentioned probably would be best bet.

Fan shroud has one screw on left and a clipping mechanism on right with a tab that needs to be pushed to release. Plus the fan electrical connector that needs to be disconnected. There is another cable that clips onto some connector/sensor on the left that should be either disconnected or moved to side from what I remember. I have the same year and model as yours.
Fan shroud is easy to remove.

Putting it back make sure the tabs on its bottom go into the receiving holes correctly.

bimmaone · 08-21-2015, 12:54 AM

SOLVED! A combination of tool saved the day
1) purchased grip-tite tool kit from sears (auto zone has a similar kit)
2) used the 7/16 torx bit to try removing the bolt but it was too loose, and 3/8 was too tight to fit the bolt
3) looked around the garage and pulled a large plier which made a dent on the edge of the bolt, but then I figured maybe the 3/8 could fit now
4) tried the 3/8 bit again and voilà it worked
5) so definitely using wrong tools was a large contributor to the stripping. The newer tensioner was delivered with two bolts, and I was able to reinstall the stripped tensioner you see in the picture with an E14 torx star and T60 bit. I now have a spare tensioner that I might return . My breaker bar was also two short and did not help. Car is running again with full power steering and AC. CEO is happy too!

Thanks everyone for the help

08-19-2015, 12:32 AM	#1
bimmaone Enlisted Member 16 Rep 48 Posts Drives: '18 F15 xDrive35i Join Date: Feb 2015 Location: North Texas iTrader: (0) Garage List 2018 BMW X5 xDrive 35i [0.00] 2013 328i [0.00]	Belt tensioner stripped bolt - 2006 325i E90 N52 engine Hi bimmers, I'm unable to remove belt tensioner because of a stripped bolt . if you look at the picture you will notice I also messed up the torx T55 socket. The nail on the coffin, it was a brand new tensioner I was replacing. I was told to hammer in a smaller torx socket to tighten the bolt and unscrew it, but there is not enough clearance to do so without damaging something else when I attempted it. I will appreciate any ideas to pull this off. A new tensioner should be delivered tomorrow. Thanks in advance for your help. Attached Images
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08-19-2015, 06:10 AM	#2
davidwarren Captain 187 Rep 670 Posts Drives: 328,325, 325, 335, X5, 640 GC Join Date: Dec 2011 Location: Louisville, ky iTrader: (0)	That looks bad. It may be easiest to just go ahead and pull the radiator and drill it out.
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08-19-2015, 06:15 AM	#3
Wingnut335 Lieutenant 71 Rep 477 Posts Drives: 2011 E90 335XI Join Date: Mar 2013 Location: Chicago, IL iTrader: (0)	I think it needs to be drilled out as well. I've stripped many screw heads and this one is up there in terms of how much of the head is gone. A screw extractor won't work on this.
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08-19-2015, 07:16 AM	#4
robthewrench Captain 266 Rep 952 Posts Drives: 11 E90 335i Join Date: Aug 2014 Location: Columbus OH iTrader: (0)	You'll need to drill it and then either hammer in another torx socket or use a really big screw extractor bit. You may have to pull out other systems to get the clearance you need. __________________ bone stock
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08-19-2015, 07:49 AM	#5
lookalikehuuh Major 700 Rep 1,227 Posts Drives: 2006 330i, 2007 335i Join Date: Sep 2014 Location: San Diego, CA iTrader: (0)	Before you go removing radiator and such its worth trying 2 sockets... 1. These "universal" sockets which are more like spline drives could possibly pull it out. Example: http://www.craftsman.com/craftsman-9...7_00902496000P 2. Try a bolt extractor set. Ive had good luck with these in the past: Example:http://www.amazon.com/Irwin-Industri...+extractor+set Oh yea and next time make sure you are using the correct tool for the job this will prevent this exact problem.
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08-19-2015, 09:16 AM	#6
lichtgelb Lieutenant 107 Rep 485 Posts Drives: 2009 E93 335i Join Date: Mar 2015 Location: Flyover Country iTrader: (0)	If you haven't already done so, there's only two small Torx head screws holding in the fan shroud. Pulling it out will give you a lot of clearance to work in there.
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08-19-2015, 12:14 PM	#7
snayko Private First Class 34 Rep 142 Posts Drives: 325i 2006 Join Date: May 2014 Location: Gainesville, FL iTrader: (0)	I would try pliers, socket stuffed with sandpaper etc. before drilling. As I remember torque should not be too high to make it possible to unscrew it with just pliers
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08-19-2015, 01:02 PM	#8
ajaye Second Lieutenant 31 Rep 228 Posts Drives: 07 328xi SGM Join Date: Dec 2014 Location: Pittsburgh iTrader: (0)	Since you can't hammer something on as-is, there's a small possibility you can JB Weld a socket over the bolt, let it set up and remove. It may be worth a try but I wouldn't bet on it. If that fails, just get a dremel and knock the head off the bolt. Its aluminum, it will grind off very easily, once the head is gone there will be no tension and the remaining shaft will spin out by hand.
	Appreciate 0 Quote

08-19-2015, 01:13 PM	#9
davidwarren Captain 187 Rep 670 Posts Drives: 328,325, 325, 335, X5, 640 GC Join Date: Dec 2011 Location: Louisville, ky iTrader: (0)	I take my suggestion back. I looked at it this morning and I was thinking the socket you use to relieve the belt tension was the fastener. The bolt you need to remove is in the center of the spring. That one still looks salvageable without going straight to drilling. __________________ 2010 335i e90 Le Mans Blue/Chestnut Brown \| M-Sport \| 6MT
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08-20-2015, 06:58 AM	#10
bimmaone Enlisted Member 16 Rep 48 Posts Drives: '18 F15 xDrive35i Join Date: Feb 2015 Location: North Texas iTrader: (0) Garage List 2018 BMW X5 xDrive 35i [0.00] 2013 328i [0.00]	Thanks for your replies. I should have more time today after work to continue the salvage operation. I will probably remove fan shroud to give myself more room as suggested. Will keep you posted
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08-20-2015, 09:04 AM	#11
MahiC Banned 88 Rep 138 Posts Drives: 2013 e92 m3 ZCP Jet Black . Join Date: Dec 2012 Location: San Jose, California iTrader: (0)	Hey I messed up the t 60 socket to relieve the belt tension as well. How would I go about taking the pulley off?
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08-20-2015, 10:00 AM	#12
TheBigYahi Private First Class 40 Rep 164 Posts Drives: 2006 330xi 6MT Join Date: Jun 2014 Location: Syracuse, NY iTrader: (0)	I'm pretty sure that the Torx socket is a T60, so that's probably why you stripped that part. As for the bolt, you could try a bolt-out socket on a long ratchet. That's how I managed to get out a pesky OFHG screw out. This is the set I have. Not sure if the biggest size will fit the tensioner screw. You might need to hammer it on a little bit to get it to bite. I don't recommend using a drill for removing Torx bolts because you'll eventually round it off to where the bolt-out won't work.
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08-20-2015, 12:44 PM	#13
Greyfox Colonel 1208 Rep 2,835 Posts Drives: 2007 328xi E91 - 330k+ (miles) Join Date: Feb 2014 Location: USA iTrader: (2)	If you are talking about that center bolt... get a good set of vice grips and lock onto it as tight as both your hands can squeese. Then get a big pair of channel locks and use them to turn the vice grips.
	Appreciate 0 Quote

08-20-2015, 01:05 PM	#14
PhaseP Colonel 1007 Rep 2,108 Posts Drives: 325XI Join Date: May 2010 Location: Earth iTrader: (0)	With fan shroud out, you should have just enough clearance to use a big heavy hammer sideways on its side face, not on its regular hitting face. Hammering in one of those extractor sockets mentioned probably would be best bet. Fan shroud has one screw on left and a clipping mechanism on right with a tab that needs to be pushed to release. Plus the fan electrical connector that needs to be disconnected. There is another cable that clips onto some connector/sensor on the left that should be either disconnected or moved to side from what I remember. I have the same year and model as yours. Fan shroud is easy to remove. Putting it back make sure the tabs on its bottom go into the receiving holes correctly.
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08-21-2015, 12:54 AM	#15
bimmaone Enlisted Member 16 Rep 48 Posts Drives: '18 F15 xDrive35i Join Date: Feb 2015 Location: North Texas iTrader: (0) Garage List 2018 BMW X5 xDrive 35i [0.00] 2013 328i [0.00]	SOLVED! A combination of tool saved the day 1) purchased grip-tite tool kit from sears (auto zone has a similar kit) 2) used the 7/16 torx bit to try removing the bolt but it was too loose, and 3/8 was too tight to fit the bolt 3) looked around the garage and pulled a large plier which made a dent on the edge of the bolt, but then I figured maybe the 3/8 could fit now 4) tried the 3/8 bit again and voilà it worked 5) so definitely using wrong tools was a large contributor to the stripping. The newer tensioner was delivered with two bolts, and I was able to reinstall the stripped tensioner you see in the picture with an E14 torx star and T60 bit. I now have a spare tensioner that I might return . My breaker bar was also two short and did not help. Car is running again with full power steering and AC. CEO is happy too! Thanks everyone for the help
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