Rounded Hex

[Ovrhill]

Have a rounded out hex connection on top of a front strut. Can't hold the shaft in place to remove the top nut.
Tried an air impact with no help. Shaft still just spins.
Looking for suggestions on removal without damaging the strut. I plan to reinstall it with a new mount.
Also tried some heat. No help either.
Any ideas?

 

[STDOUBT]

Which nut is it? The one right on top of the mount?
There's a (usually) 7 mm hole for an Allen bit to hold the shaft in place while you turn.
Maybe something like this - a pass-through bit, slightly smaller than the nut pounded onto it might grip enough to allow it to turn while you hold the 7 mm Allen in there:

16mm Strut Nut Socket - CTA Manufacturing 3039X01

16mm Strut Nut Socket - CTA Manufacturing 3039X01

www.fcpeuro.com

 

[ts888]

Split a piece of heater hose so it can be slipped over the shock shaft and clamp it with a large locking plier (aka Vise-Grip).

 

[Ovrhill]

Which nut is it? The one right on top of the mount?
There's a (usually) 7 mm hole for an Allen bit to hold the shaft in place while you turn.
Maybe something like this - a pass-through bit, slightly smaller than the nut pounded onto it might grip enough to allow it to turn while you hold the 7 mm Allen in there:

16mm Strut Nut Socket - CTA Manufacturing 3039X01

16mm Strut Nut Socket - CTA Manufacturing 3039X01

www.fcpeuro.com

It's the top nut and I have a proper 7/8 deep socket and a long hex to slip through the center.
But, the hex connection on top of the strut shaft is rounded out. Can't get a grip to keep the shaft from rotating.

 

[Ovrhill]

Split a piece of heater hose so it can be slipped over the shock shaft and clamp it with a large locking plier (aka Vise-Grip).

I might try that. I just don't want to damage the threads or get it out of round.
Someone really cranked the nut down.

 

[Brett San Diego]

Vice grip may work. If you can grip it up high enough, you can probably be above the "working" section of the shaft that goes into the shock body at full compression, so you may not need to worry about protecting the shaft. I don't know where that point is on the shaft.

Try hammering a slightly oversize torx bit into it so long as you don't mind buying a new one. Or go to Harbor Freight and buy a new set of torx bits first and try it. If you damage or break it, lifetime warranty.

Last resort, cut a slot in the shaft with a Dremel tool and cutoff wheel, and use a large flathead screwdriver or other suitable tool to counterhold the strut shaft.

How to you intend to tighten the strut nut when reassembling?

Brett

 

[Ovrhill]

Good advise.
I tried hammering a larger hex into the rounded hole. I just made the rounded hole larger in the end.
I have not seem the pipe nipple extractors before.
I'll explore that one.

 

[Ovrhill]

How to you intend to tighten the strut nut when reassembling?

I haven't started thinking about that yet. Just know that I can't mess up the threads getting it apart.

 

[turbodieseldyke]

What a retarded design this is. These VW morons and their 6mm hex screws everywhere. This is what happens when you lose a war. You lose all hope for the future and you do stupid crap like this because nothing matters any more.

 

[Ovrhill]

I'm still in the fight.

It's no worse than most of the other designs that I have seen. They are all a lttle messed up.

 

[Steve Addy]

I'm still in the fight.

It's no worse than most of the other designs that I have seen. They are all a lttle messed up.

You might try an SAE allen (hex) bit and file / grind it down just a tad and then tap it into the hole.

These strut nuts need to be soaked liberally before removing and I don't use deep sockets or long allen bits if I can help it. I know my method is wonky but I take a large vice grip and tightly clamp it to a standard 1/2" drive 21/22 (which ever it happens to use) and then drop a short allen (hex) bit down through the center and use a 3/8 to1/2 adapter and breaker bar to hold it while it undo the nut with the vice grip 'wrench.' It sounds ghetto but it's never failed me and I've used it on some very old and crusty strut tops....cuz you know the protective covers are always missing!!!

The other key is to only use the hex bit to hold the strut in place, do the loosening with the wrench part on the nut.

That's my 2 cents on this...

Steve

 

[Steve Addy]

What a retarded design this is. These VW morons and their 6mm hex screws everywhere. This is what happens when you lose a war. You lose all hope for the future and you do stupid crap like this because nothing matters any more.

Oh that's nothin...it's torx everywhere now...everything is torx...FFS.

Steve

 

[Shenandoah]

I had this happen on one of my mk4 VWs. I drilled holes all around the nut in the metal "cup" that goes on before the nut. I was then able to remove the strut (nut still on). I have four parts cars, so I was able to take one off the parts car to replace the one I had to destroy to get the strut out.

Not sure what this part is called, but it is the round cup with the rubber ring around the edge that hold the strut in place. It's right under the nut you are trying to remove.

Eric

 

[Zak99b5]

Since the hole is rounded out already, maybe try running a tap in it. Then insert a bolt in there, tighten in down, and counter-hold with that?

 

[jimbote]

I had this happen on one of my mk4 VWs. I drilled holes all around the nut in the metal "cup" that goes on before the nut. I was then able to remove the strut (nut still on). I have four parts cars, so I was able to take one off the parts car to replace the one I had to destroy to get the strut out.

Not sure what this part is called, but it is the round cup with the rubber ring around the edge that hold the strut in place. It's right under the nut you are trying to remove.

Eric

Might be called the strut retainer plate?

 

[jimbote]

Maybe try hammering an oversize torx bit into the hole. And oh yeah, NEVER use an impact to install that nut. It's okay for removal but when you use an impact to install it it ends up spinning the shaft out of the strut assembly nut. Then you've got a loose stack going on and it causes weird handling and crazy wear on the strut shaft.

 

[Bradm]

I had this happen on one of my mk4 VWs. I drilled holes all around the nut in the metal "cup" that goes on before the nut. I was then able to remove the strut (nut still on). I have four parts cars, so I was able to take one off the parts car to replace the one I had to destroy to get the strut out.

Not sure what this part is called, but it is the round cup with the rubber ring around the edge that hold the strut in place. It's right under the nut you are trying to remove.

Eric

Spring hat/top hat

 

[Ovrhill]

Since the hole is rounded out already, maybe try running a tap in it. Then insert a bolt in there, tighten in down, and counter-hold with that?

That idea, if it were to work, would give me a way to reinstall the assembly as well.
I'll be back on it this morning and will report back.
Appreciate everyone's ideas.

 

[JDSwan87]

Useless knowledge:
That type of joint is called a "hold-n-drive".
https://www.google.com/url?sa=t&sou...IQFnoECBIQAQ&usg=AOvVaw0yvvfQ7ETvgrSylQEMbkHC

 

[Ovrhill]

Tapped the hole and ran a M10 bolt down to counter the nut. It was still a bear. Had to cut into the nut, hit it with a chisle, and torch it before it finally broke loose.

Thanks for all of the advise!

 

[Nuje]

Nice work!
(And great suggestion / solution put forward by @Zak99b5! )