I am replacing my rotors and pads, and when I was removing my driver's side front rotor, the head of my impact driver broke off in the head of the screw, but it broke off almost flush so I cannot put another philips head into the screw! Everything was going so smoothly until this happened and now I do not know what I can do...I have tried using a nail to try and hammer it out from an angle and I have tried pulling them out with pliers but there is not enough surface area...are there any tools or techniques that are out there to get my rotor off??? Please help!!!

 

Torch it.

Then go to Sears and buy a tool kit for stripped screws. It's not expensive.

 

Here's what I would do - I'm sure Kris could probably give you another approach.

1. Get a punch that has a sharp point and place in the middle of the screw.
2. Whack it really hard a few times with a hammer to get a nice dimple into the head of the screw area. Purpose being for step 3.
3. Get a drill and drill it out. The punch is to help center and keep the drill aligned.

You really don't need the screws after you install the new rotors.


Edit: PA above also has a good idea. If you have a propane torch, you can heat up the screw. Assuming the screw and bit have different expansion coefficients, it may help loosen up the bit where you can get it out. However, I wouldn't torch it too long as I would worry about the affects of that much heat getting to the wheel bearings. (May or may not be an issue, but I'd rather not find out the hard way).

 

just hold a torch to it and then use a screw extractor (that's what they are called, right?)? Torching it won't damage or warp anything important?

also, it is not dangerous to leave the screws out for any reason?

 

I would torch it for a few minutes, directly aimed at the broken piece. Since the impact screwdriver bit broke before the rotor screw did, you have a pretty good idea of which one is stronger.

Once it's all heated up, give it a solid hit with a punch (or a smaller screwdriver or something that you can squeeze in there) and a BFH (big fucking hammer). If you further strip the rotor screw to a point that you cannot get a screwdriver bit in there, then go to Sears.

 

thanks for the tip on the torch! It worked very well!

 

Glad i could help!

 

You could have drilled it out too.

 

that exact thing happened to me. i got a crowned 9/32' titanium drill bit. dipped in some good ole 5w30 oil. each screw took about 20 seconds, dont push too hard, let the bit do the work. i broke 2 impact driver tips trying to get them off and about 1.5 hrs of hassle. word to the wise, drill em. it took only 20 mins a corner if you drill. hope this helps the next person. those screws are useless, and annoying.

 

Placing a ball peen hammer on the screw, then smacking the hammer with another hammer works well to break it loose and push the screw head tighter together for easier removal.