Amc 20 differential cover bolts

[ScottB]

I'm having major problems getting the AMC20 cover bolts off. I scrapped all the crud off of the bolts and around them. I hit them three times front/back with Deep Creep over three days, tapped them with a hammer, and only managed to get one off. I snapped a T40 Todd bit off on one. Haven't stripped any of the heads yet, but I can't get any of them to budge. Thought about using a torch, but a little leary with the fuel tank there. Any ideas?
Also, can't get a socket extension into the fill plug. Looks like the previous owner buggered it up. Any ideas there?
Thanks
Scott

 

[Old Dog]

Don't know if you know or not, but the taped holes and maybe the bolts go all the way through on most of the holes. Try spraying and cleaning the backside also, it might help.
As for the fill plug if you can't drive an extension into it I not sure what you could do short of drilling and using an easyout.

 

[gert]

Good day neighbor, try using a punch and hammer on the side of the head of the bolts to help shake the rust loose, and then put the torx back on it and smack the out of the head of the screws, I had to use an impact wrench on a lot of the torx bolts on my jeep. Good luck

 

[IOPort51]

My favorite tool to use on torx bolts is an impact driver. One of those things you hit with a hammer that has a 3/8 end to hold a socket.

Impact Driver Set | AutoZone.com

I promise it will be some of the best money you will ever spend for loosening rusted bolts, especially torx. Make sure you have good Torx sockets, Kobalt, craftsman, snap on, you will twist a cheep one like an easy out. I have tried an impact wrench with Torx sockets and it just stripps the head, this thing turns and drives inward at the same time.

I like a mixture or 1/2 acetone and 1/2 ATF . works better than anything I have found in a spray can.

 

[ScottB]

Thanks for all the ideas! I'll get after them today.

 

[CJim7]

Once you get them out....replace with standard bolts. It will make life easier in the future.

 

[mtnwhlr]

I agree with IOPort51 a impact driver is a must have when working on old Jeeps.

 

[Flex BT]

I had to use a set of vice grips around the heads. The impact driver did not work for me on the fill plug, I ended up (nervously) using a breaker bar and that did the trick for me. Be sure you replace those bolts with hex heads from Napa or somewhere, the home depot and lowe's bolts are s___.

 

[ScottB]

Well, tried an impact driver (Performance Tool) from OReillys. First one jammed after a few blows. Second one would not rotate counter clockwise. There will not be a third one. OReillys guy said Performance Tools are and I would have to agree. Ordered a KD Tool. Let you know in a few days. Already have grade 8 hex heads ready to go in. On a positive note, got the fill plug out.
Thanks Scott

 

[jasonmark1993]

man what a crappy feeling to be selling someone something knowing that it sucks.

At least he was honest with you.

 

[mtnwhlr]

If it came from O'Reillys then more than likley it was made in China like about every thing else they sell. I got mine from Snapon and has worked great for many years.

 

[IOPort51]

those are pretty simple machines, you would almost have to work at building a crappy one. I have had a Craftsman for quite a few years and have even found replacement Philips head drivers for it on line.

I would expect way more problem with cheep Torx drivers. I bought a set at vato zone many years ago, they twisted so easily it was almost comical.

you should try the acetone ATF penitrant. just apply to 1/2 the bolts and see if there is a difference.

Well, tried an impact driver (Performance Tool) from OReillys. First one jammed after a few blows. Second one would not rotate counter clockwise. There will not be a third one. OReillys guy said Performance Tools are and I would have to agree. Ordered a KD Tool. Let you know in a few days. Already have grade 8 hex heads ready to go in. On a positive note, got the fill plug out.
Thanks Scott

 

[ScottB]

Success!! Many thanks on the ideas. No drilling/tapping required. The BFH and cold chisel worked best. A couple of bolts came out with a little extreme pressure on a Torx bit. Kudos to Kobalt. Their Torx bit is way better than anybody else I tried.
The bad news is I found out the OE differential cover is about rusted thru. So on to research covers. Any recommendations for cover? Not looking for anything extreme. Spend 95% time on the road.
Thanks Scott

 

[CJ]

Congrats on the bolt reveal!

As far as a replacement cover goes, IMHO - just buy an OEM replacement - heck the original lasted 30 or so years!

 

[gert]

lol way to go BFH if you stay on the street then the Kentrol stainless cover would be a good choice Kentrol Stainless Steel Rear Differential Cover AMC 20 304M20