Hi,

My polo needs new front brakes. I have started and got the upper caliper retaining bolt undone but the lower one has been rounded off. I am open to Ideas for getting it out. Tried screw extractors but not enought depth in the hex/round hole. Could drill further but then risk weakening and shearing them. Plus they're grade 8.8 so I imagine drilling won't be a walk in the park. Thought about welding something on like a bolt so I can undo it that way. Trouble is there is a rubber shroud around the bolt. Does this come off easily? If so I might be able to try mole grips too. Really not having much luck. Any thoughts would be much appreciated. Maybe you have had the same and found a solution. I have brand new bolts ready to go so I am quite happy to destroy these ones.

See pic below for location. Thanks in advance.

Hi,

My polo needs new front brakes. I have started and got the upper caliper retaining bolt undone but the lower one has been rounded off. I am open to Ideas for getting it out. Tried screw extractors but not enought depth in the hex/round hole. Could drill further but then risk weakening and shearing them. Plus they're grade 8.8 so I imagine drilling won't be a walk in the park. Thought about welding something on like a bolt so I can undo it that way. Trouble is there is a rubber shroud around the bolt. Does this come off easily? If so I might be able to try mole grips too. Really not having much luck. Any thoughts would be much appreciated. Maybe you have had the same and found a solution. I have brand new bolts ready to go so I am quite happy to destroy these ones.

See pic below for location. Thanks in advance.

Try using a torx bit, the one that looks like a star when you look at it...thats how i got mine off, i had just enough grip to turn it. i dont see no point drilling the actual head of te bolt because you cant actualy slide the caliper off afterward. you need to take the crew out. if all else fails try drilling a small hole in the middle of the bolt, try not to hit the thread then get something with a left handed thread or something that is the oposite to the bolt and screw it out. The sheath...i just stuck a stanley knife through mine...

yeah rip off the rubber and try mole grips...but they're usually tight so hammering in a torx bit will probably work better

Try hammering a torx bit ,the hammer blows help to loosen it off,if that then also rounds out try a multispline bit, if all else fails,cut the sleeve off and get your chisel out!!

8.8 grade is not to hard to drill out after all else fails !! when you have tried everything else people have suggested and are scratching your head then drilling out to 8.25 or 8.5 just to get rid of the bolt right down to the part past the caliper ! assuming youve drilled square then it should come you just need to measure the bolt you have removed to find out how far you need to drill the existing bolt before the caliper will come free ! hope this helps

You can use an extractor,just you'll need to grind the tip so it starts biting straight away,and drill into the bolt with a 6mm drill bit for another 1-2mm deep to get the required clearance for the extractor. If that fails,drill the head off,using a 9mm bit,then drill the stem with a smaller bit,say 5mm,and use a smaller easy out to suit - the head is holding the torque,and the stem will be far easier to turn out with the head off.

I can see Jaycee's thinking,but the chances of drilling straight down a bolt stem..

You can use an extractor,just you'll need to grind the tip so it doesnt bottom-out and starts biting straight away instead - and drill into the bolt with a 6mm drill bit for another 1-2mm deep to get the required clearance for the extractors chew-in. If that fails,drill the head off,using a 7-8mm bit,then drill the stem with a 3-4mm,and use a smaller easy out to suit - the head is holding the torque,and the stem will be far easier to turn out with the head off,so the little easy-out should work fine.

Cheers for all the reply's gents. I spent an hour and a half last night with a lump hammer and various size torx bits. Got the O/S one in about half an hour. The N/S one was bad so held me up big time. Hey who cares though they are off and the new discs and pads are in along with shiny new bolts (put in with copper grease and a ratchet very gently). Sure windy guns are very useful in garages but I hate them soooo much.

Was up till 2 this morning trying to rebuild the rear brakes. Decided to pack in as doing bearings is a bit noisy for my neighbours! Looks like I'm missing dub preservation tonight to finish assembly the rears & change a wheel cylinder. Never mind hopefully she'll be ready for Santa Pod this weekend. USC here we come. Can't wait.

Cheers again for all your advice.

Regards

Sam.

I've got exactly the same problem. Assuming I can remove the retaining bolts with a torx bit (spent 3 hours playing with mole grips last week then had to put it all back together!) where will I be able to obtain the new ones from?

Similarly the bleed screws on the calipers for the brake fluid are also totally siezed - could overhaul the whole unit, but not sure where to get the bleed screws from. Are these a standard universal part? Is my best bet to recondition the calipers myself?

Would appreciate any advice!

yeah rip off the rubber and try mole grips...but they're usually tight so hammering in a torx bit will probably work better

That's the way to do it. Garage did that for Imrie's when it was being a dick.