Front rotor allen bolt stripped, now what?

[foofopps]

So I'm doing my brakes all around, pads and rotors. Im done with the rears and had no issues. On to the front and the driver side 5mm allen is stripped out completely! Has anyone had this happen to them? What should I do? The only thing I can think of is 'carefully' taking the rest of the allen head off with a grinder, then pull the rotor off and I'll have a bolt that I can work with. I used PB blaster prior to it stripping out. Any better options before I go to town on this with a grinder?

[N2MYE30]

5.5mm allen with a hammer. I cannot remember the standard size thats a bit bigger than the 5mm but same concept. Hammer the larger allen in as far as you can. BTW, this has happened to me several times...what a pita! I now stock new rotor screws.

[redhatpat]

and if that ^ doesn't work, grind away. You're replacing the rotor anyway.

When you put it all back together, use new screws and don't over tighten them.

[kts]

few options i've seen when people ask about this:

- 5.5mm allen w hammer
- cut a channel with a grinder/Dremel and use a big screwdriver to undo it
- drill out the head, remove rotor, use vise grips or something to remove what is left of the stud
- weld bolt/nut to it and remove

[Dermeister3]

theres a tool that is an allen wrench with a handle, that when you tap the back of the handle with a hammer, it torque the wrench hella hard andalmost always pops it.

Not sure of the name of the tool

[lolcantturn]

Drill through the head of the bolt, then pull the rotor off.
The bolt serves virtually no purpose except making it easier to keep it on there when you're installing everything. In which case, you can just screw a regular lug nut to keep the rotor steady.

[robmespeedy]

grab a punch with a sharp tip. on the outside of the hex punch it. once there is a small dimple, punch thru there but in the direction to loosen.

[Farbin Kaiber]

Impact Screwdriver, this is just an example, there are many types. It would have been the tool to use.

[ck_taft325is]

Impact Screwdriver, this is just an example, there are many types. It would have been the tool to use.

Do want. Talk about making a billion odd jobs easier.

[nando]

it should never be possible to strip one of these.

A) use copper anti-seize
B) put it in FINGER TIGHT

I realize the OP may not have put it in there himself, but I think most people put the bolt into a rusty hole, and then wrench it down as tight as they possibly can. If you do it right you can even reuse the setscrew a few times.

[BigTe30]

^ impact driver will work perfect, i got mine for 9$ at harbor freight.

However when i stripped the retainer bolt on my rotor, i used a striped screw remover. I had to drill out the allen bolt a little and the twist the remover in there. The drill didnt have enough torque to remove it so i clamped some vice grips on it and gave it hell.

and Nando, +1 on the anti seize, worth its weight in gold

[nando]

the easiest thing IMO in this case is to drill off the head of the bolt, remove the rotor, and then extract the stub with some vice grips.

[Hick]

Do want. Talk about making a billion odd jobs easier.

lol, you say that now... if you plan on using one of these, make sure you have AT LEAST 5 extra bits lying around

[foofopps]

Tried the 5.5mm with no luck. Little grinding.

[foofopps]

Little hammering. Thank you all for the quick responses thats what this forum is all about!

Now im going to soak the hell out of that bolt with PB blaster before I strip that.