Someone rounded off a $&#%!!! Allen bolt

rocky

Well-known member
Trying to remove a rounded off Allen bolt on the fan clutch. The other three came free nice and easy, but one was rounded off by whoever put it on....
I've sprayed on a bunch more on PB blaster on it and letting it sit.

Is there anything like a damaged screw remover for allen bolts?
 

WK2Burner

Well-known member
My usual go to has been to dremel slots in to get. Flathead in there. I think extractor sets at the HW store will work. Drill and reverse tap style.

I guess it's a difficult spot to work on?
 

rocky

Well-known member
Not difficult, its sitting on my workbench...Its a spare fan and old bad clutch that I decided its time to separate.
 

ezzzzzzz

Well-known member
Are you trying to save the clutch, fan or both? If you have a mig you can weld in a small bolt to aid removal.
 

galen216

Well-known member
Someone gave me the advice once of using a torx bit. Use one slightly larger than the opening and hammer it in.
 

4wdtravel

Well-known member
hi chris, that would be easy to drill out as the bit would self center in the socket head. or, this style of extractor work well if you want to try.



adam
 

NPT90

Well-known member
My usual go to has been to dremel slots in to get. Flathead in there. I think extractor sets at the HW store will work. Drill and reverse tap style.

I guess it's a difficult spot to work on?
Thats a solid idea. Option B would be to cut off the head and tack weld a metal piece once you get the pulley off. Likely easier without the pulley in the way
 

O2batsea

Well-known member
Or if you have a spare allen wrench you aren't particularly fond of, stick it in there best you can and then weld it to the bolt with a couple blobs. Let it cool before you grab the wrench! (duh) The combination of heat and twist will solve your problem.
 

rocky

Well-known member
Tried that so it came down to drilling the bolt head until the head broke off.

Have opened up the bolt holes and installed a heavier duty fan clutch. Let's see how it does this weekend in the woods.
 

rocky

Well-known member
Well.....three hundred or so miles later. One day spent at a local garage getting a replacement fuel pump, and a second day on the trails, I reckon I have a success on my hands with a replacement fan clutch.

Hayden describes three fan clutch performance levels, Standard, Heavy Duty and Severe. Digging through another Rover forum (not dedicated to Defenders), I identified the advanced auto PN 215158 as a severe duty fan clutch, and 215157 as heavy duty. Severe being for the toughest cooling challenge. Since I have a bad habit of overdoing stuff I got the severe duty version. Plus a a Dorman help kit 14040 (four 10mm bolts) and finally a 25/64ths drill bit cos I couldn't find a 10mm version and 3/8s was too small.

I doubt outdoor temps exceeded 70F this weekend. On the road, water temps happily stayed at 180 until I found a few good hills on I91 in VT and intentionally accelerated to stress the cooling system out. It rose up to 195/200 region but dropped back down as soon as the road leveled out. It will idle at 175-180 in a parking lot. Some people say its a louder fan set up. It may be, but no louder than the start up noise you get from the stock unit.

In the back of my mind, I can see having a winter set up, (standard duty) which will cool less and allow more heat output from the heater. This severe version will be better in spring or summer.
 

Napalm00

Well-known member
No , reaching behind the hard plastic fan shroud on a 200 and 300 sucks.

I try to convince every person's truck I work on to move to Electric

I'm specifically talking about putting the fan clutch back on taking off is easy. And yes I do have the one tooth spanner and a properly sized fan clutch wrench
 

rocky

Well-known member
I'm going to swap out the 215158 fan clutch back to the normal one which is a Uro branded part.
As temps drop, I think its keeping the engine a little too cool, under 180, so the heater sucks more.....25 degrees last night and first snow tonight....dammit wheres the snow blower...
 

66rover99

Active member
I just want to clarify, is the 215158 Severe Duty fan clutch for 300 TDI or a v8? I have a standard duty clutch on mine that generally seems to be along for the ride and I can't sense any engagement. Was looking for a more hefty alternative.

cheers.
 
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