The bolt that defies EVERYTHING

So, the previous owner stripped off the corners on the bolt holding my old oil filter on. I want it all off, so I can install the new spin-on.

But It doesn't want off.

I've tried WD40
I've tried vice grips
I've tried the drill and tap method
I've tried a bolt extractor socket
I've tried a torch.
I even tried using a drift and hammer to get it to move.

What the hell else can I do? This thing does NOT want to come off. NO idea what the hell this guy did to lock it all down so tight. Now it's even worse. Rounded completely, and drilled out the center. I'm stumped

 

But, in case you do come across one of these bolts that is seized frozen tight, here’s how to make it “take one for the team” and get it off:

http://www.xjbikes.com/forums/index.php?threads/im-back-and-my-f-in-oil-filter-is-stuck.55021/

 

Read what I said about grinding the head off. You're NOT going to ruin anything that's unobtanium. These parts are plentiful.
-Grind it
-Remove the filter housing and filter
-Unscrew the remaining part of the bolt and throw it away
-install s new one and DONT tighten the snot out of it
-put back together
-fill it
-go ride

 

Jesus! Don't Fecking remind me of that nightmare!! May the force be with you sir..

 

Meh--- it's only a nightmare if you're determined to try and save it. It's not worth that hassle. Just grind the head back pop the cover and put a new bolt on.
I've done that probably half s dozen times now.....

 

Well if you don't care about the cover/case another option is to just chisel or grind off the tab that stop the filter case from spinning - then you can just turn the whole thing

 

Too much trouble given how easy the head of the special bolt is to grind off.
New filter bolts are still being made. New filter housings are not, and some day they will become hard to come by.

 

I wouldnt do that----

 

just check out one of those random xj nut and bolt collections on ebay. There are often one or two in a batch

 

I believe cutting the tabs also works on the baptists ministers wife's pants but that's just hearsay. or is that heresy.

 

If you have a dremel tool use a cutoff wheel and zip the head off of bolt. I see your going to the spin on filter good up grade did this to my 750 seca..thanks chacal great upgrade and no more siezed bolt...

 

If you don't upgrade to the "spin-on" filter type and plan to use the housing again, they make a bolt with a larger head to replace the one you had to sacrifice You may have has the smaller head version). Chacal has it. That's where I got mine!

 

My plan's been to upgrade to the spin-on filter. I've already got it sitting here - that's why I started this insane little task. I'm fast approaching "how do I just angle-grind the whole original filter housing off?" I've already cut a groove across the whole head of the bolt, including the washer portion. I've been using cold chisels to try and hammer it around, but nothing is moving. Maybe I'm doing something (or everything?) wrong, here, but at this point I'm perfectly fine with utterly destroying the original filter housing unless anybody's got a better idea? I'm starting to wonder if the P.O. cross-threaded things somehow... but I would've thought I could still force it back out.

It's hard to get a grinder in there. I tried one cut across, and another at the only other angle I could manage without hitting the pipes. Here's the hell I've created for myself. It hasn't moved even a hair. It acts as if it is one with the filter housing.

 

If your cutting/disc won't reach, try a grinding stone on a drill to get in there. You've got to nibble away at it. She'll fatigue and break away at some point in your endeavors. If you don't have one, run to your nearest home depot or lowes now while they are still open, its getting late and its sunday!

...or perhaps, call it a day on this. You might just do more damage than good if you're frustrated. Put the tools down and pop open a cold one. She'll wait for tomorrow.

 

@hogfiddles so what's the problem with just snapping off that tab - seems easier. If you have a lift and the "right" grinder I can see getting that bolt down isn't that hard if not getting rid of that tab seems like a no-brainer. Just trying to understand the issues!

 

At this point, the sun's getting low, so I've got no choice but to quit for now... on day two of fighting this bolt from hell. I swear there must be something I don't understand about how this comes off?? What am I missing. Does the whole housing need to be cracked loose from it?

I've now used the wheel to grind off the entire top of the nut to the washer, and tried using the chisel again. Nothing. I thought this had some spring in it that it would release at some point?.

Can I just grind the filter housing in half? or cut it out around the bolt with a grinding stone? There has to be a way.

Hah! No beer for me... I had too many last night, with friends, to forget a day-long, expensive attempt to get this bolt out.

 

I saw mention of "tabs" but not sure what that means?

 

see here https://www.ebay.com/itm/MAXIM-700-XJ-750-650-OIL-FILTER-COVER-BY-PASS-VALVE-ENGINE-MOTOR-PARTS-YAMAHA/202085939071?fits=Model:XJ650&hash=item2f0d42b77f:g:Rl4AAOSwDNdVque1&vxp=mtr

The little tab thing that sticks out from the housing! it helps to align the cover and seats into place on the engine-block - I believe it's the only thing that stops the whole cover from being able to spin. If you can break that off you should be able to turn the whole housing along with the internal screw and just spin it off. The smart dudes here are advising against it though so I'd want to understand the reasons for that first besides destroying the cover. Also, there might be something different on the 750 I'm not aware off but this seems like ok on my 650

 

Ok, I see it.. But, yeah, I'll wait to see what others say. I'm curious about the reason we shouldn't grind off that tab.

 

That is correct.

The bolt is seized and there is an o-ring on the shaft of the bolt, just below the head (1/8" or so) that is also probably seized. If you've cut the entire bolt head and the integrated washer off, and you still can't the cover off, then either you start destroying the cover or you get a small torch/heat gun and head up the COVER (in the area close to where the bolt come thru) to get the cover to expand a bit. Might want to shoot some penetrating fluid in there too. Once that bolt freezes to the cover, it can be a real beast to remove........

 

I see so many on flea bay but somehow I want to agree with you

 

Smart dudes are concerned about wasting a housing. But from what I can tell there are far more housings than working motors (e.g. I have 4 housings and 2 viable motors..)

 

Uh... I just broke the tab off. Still not moving.

Something tells me, this housing is just going to have to be carved up.

 

I think you already cut into the housing by using the cutoff wheel to begin with. I use my cheap harbor freight angle grinder with a regular grinding wheel and grind the head off with that. I've not ruined a housing yet...... the way I approach is to grind flat/parallel to the bolt face--- level and I "layer" at a time. When I get close to done, the last little layer of the shoulder turns color, at that point the steel shoulder is paper thin and peels right off. A couple taps usually makes cover "pop" off.

If you've already cut into the aluminum of the housing, it's trashed already. Break it up.

Are there more available?---

Yup... I got some here... one has a chipped fin but otherwise fine, I can hook you up for less than buying a new one.

Dave

 

Buy a 90 degree high speed with a 7 inch cut off wheel like 25$ bucks from harbor freight if you have an aircompessor that is . That is why I suggested the dremel cut pieces of the bolt head . I recommend against cutting into the housing you do not want to get any grit the engine.

 

That's why I said break it up

 

Ok... I'm back at this bolt and housing today and still no luck.

By "break it up" and avoiding getting shavings in the engine, can I get a bit more specific description of what you mean? I just want to be sure I understand... Like, am I supposed to use a spike and anvil to hammer holes in it?? Cause, at this point, I feel like that's the only thing that will get this off.

 

I still think you should be able to grab the whole case with you hands and turn it now you broke off that tab -- just man the shit out of it dude!

 

Nope! Did that.. I even went to the store and bought a fancy "chain vice grip." I feel like there's something about this that was done wrong, or god knows what. It will not budge in the slightest. Strangest damn thing!

I've just drilled a couple holes, so the last of the oil's draining out at the moment. I had a (probably wrong) theory that doing that might break the seal and make it more possible to turn.

EDIT: Yep... oil completely drained. Still not budging.

Short of just drilling holes all the way around the center bolt, I'm open to suggestions. Brute force turning is not working.

 

Just in case there's something I'm missing, I've attached a couple images to show where I'm at now. I've completely ground through the bolt and it's washer, I've drilled three holes - one in the center (not too deep) to try and turn it. One above and one below the washer area to see if that relieved any pressure. I'm a little cautious of using a torch on anything now with oil around. The tab is down under, I've knocked that off and tried twisting it by hand... thing is, it's on the bottom, I don't see anything that would even be in the way of the tab that was there. I even used a drift at the corners or holes to try and hammer it around. No moving whatsoever.

Unless somebody spots something I'm not seeing, I'm about to just start drilling holes all around this to break it apart.



Showing where tab is broken off, this is facing the ground:

 

Eureka! Finally off! Broke most of the “fins” going around, but it finally broke loose, thanks to the long drift i got for knocking out the wheel bearings.

Sorry y’all had to put up with my frustration!

 

Wooohooo!!! Thank the maker!!

Time for a few beers!

 

PostScript: For future lost souls struggling with this one, don't fear. I'm amused to find that, after two weekends fighting the bolt that wouldn't budge, putting on the new modern oil filter took all of 20 minutes - which includes reading the instructions.

Cheers to Mr. Chacal!

Nowwww it's time for a few beers!!

 

After 4hours of flipping grinding and one broken Craftsman Rotozip, I finally got the bolt and filter cover off. I'd like to keep the orignal filter cover rather than the spin off pictured above. I have the new bolt already from Chacal! I definitely scored the filter cover a few times with the angle grinder :-(
Is this filter cover usable? Replacement bolt does seem to sit flat on cover, and since the o-ring does the sealing, will I be okay to reuse this???

1982 XJ650 Maxim

 

I'd say you're probably ok. like you said, the new bolt from Len will do the intended job and keep the bolt seal tight. Beware of cheap-o cover o rings though. I installed a "NEW" one at the first Oil Change. I got it from the previous owner with the bike. It was not "girthy" enough (for lack of a better word) and it sat in the housing groove without making much contact with the block when put in place. After install and refill of oil, I had a leak and thought I had done something wrong... It was minimal, but definitely there. If you bought your new seal and filter from Len, you did the right thing and should be fine.

 

Thanks Nuch. I have the replacement o-ring that came with the replacement Fram filter and the o-ring on the replacement bolt from Len. I’ll compare to the old seal for the cover.

 

It should be ok-- the bolt has an oil seal/o-ring in it

 

That is all.

 

If it doesn't seal, I have a couple replacements