Intake Cleaning - hit a snag...

I tried the intake cleaning this this morning and ran into a problem. The EGR cooler to connecting pipe has a stripped bolt (previous to my work)...

I got the top bolt with some difficulty (needed some PB Blaster) but my 6mm hex can't grab anything on the bottom bolt. It is rusty and crap was inside of the hex but I took a pick and dug it out. I can get the hex into the bolt about 2-3mm but it still won't grab anything. Any ideas on how to get the bolt out if stripped and rusted?

i feel ya, ive had a few intake bolts nearly strip on me too.

i would try a reverse tap first

if that doesnt work, depending on the location of the bolt thats stripped, you may be able to grind a slot into it and use a standard screwdriver... i use that trick alot.

sorry to hear about this. i really enjoy working on cars until something unexpected comes along. always puts a damper on things.

Run up to your local Sears store and grab a set of their Irwin brand Bolt-Grip extractors. They fit over the bolt, with flutes that dig in and grip the head of the bolt. They are a miracle tool for stripped Allen bolts...

http://www.sears.com/shc/s/p_10153_12605_SPM240830452P?prdNo=13&blockNo=13&blockType=G13
http://www.irwin.com/tools/screw-bolt-extractors/5-pc-bolt-grip-expansion-set

One tool that helped me out was a ball shaped socket that allows some flexibility when using it.

Good Luck

Well, I stopped my tear down at that bolt. I wasnt sure if I was going to break the bolt or what so I stopped. It was a weekend and I didn't have a spare to replace it with.

Any chance of shearing off the bolt head and really screwing myself, or will the bolt loosen before shearing...I am not worried about a mangled bolt, just worried about a broken one...