Stripped Torx Head

[AJ Huff]

Trying to replace the headlight on my truck and one of the Torx screw heads is completely rounded out. Is there a clever tool out there to get this out or do I need to drill it out, which I'd rather not do?

Thanks!

-AJ

[stormshearon]

I managed to get one "security" screw of two out of my throttle assembly on my Ducati using a similar item to this:

Womdee Screw Extractor, Easily Remove Stripped or Damaged Screws Extractor & Bolt Extractor Set Tungsten Steel Plated Titanium

The second one I drilled the head off, which allowed me to disassemble and get to the remainder and back out with a small pair of vice grips. The extractor did work really well on one of the screws, so it might be worht a try.

[John A]

Sometimes valve lapping compound on the bit will help it bite.

[Rough Edge racing]

 Is the truck old enough to have sealed beams held in place by a stainless ring? If so ,drill out the screw head..remove the stub with a small Vice Grips. If it's a square light with 4 screws, it'll be fine with just three....

[AJ Huff]

No, not sealed beams. The modern plastic shell. We lost something when headlights were no longer made by Corning glass.

-AJ

Is the truck old enough to have sealed beams held in place by a stainless ring? If so ,drill out the screw head..remove the stub with a small Vice Grips. If it's a square light with 4 screws, it'll be fine with just three....

[Rick in WNY]

If it was mine... I'd try a screw extractor. when that doesn't work I'd grab my left hand drill bits. That will either back the screw out, or drill the head so you can get to it with other means..

Good luck!

Rick

[Cam3512]

Cut a slot with a dremel for flathead screwdriver?

[AJ Huff]

Thanks. I's always been leery of screw extractors. My limited experience they made a bad situation worse. But I'll investigate. Thanks again!

-AJ

[Chuck in Indiana]

If it was mine... I'd try a screw extractor. when that doesn't work I'd grab my left hand drill bits. That will either back the screw out, or drill the head so you can get to it with other means..

Good luck!

Rick

When the screw extractor doesn't work, it's because it's broken off in the fastener. 

[OldMojo]

Thanks. I's always been leery of screw extractors. My limited experience they made a bad situation worse.

This.

I find that a slightly oversize socket mounted allen head and a firm tap with a hammer will usually coax a rounded torx out, and frequently vice-versa.

If extractors must be used - go with these:

[AJ Huff]

When the screw extractor doesn't work, it's because it's broken off in the fastener. 

Well that has been my past experience but after much internal debating I decided I would at least give it one attempt. Ordered this https://smile.amazon.com/dp/B07VFM3Q5Y/ref=cm_sw_em_r_mt_dp_U_IvfEDbW1WMGN2 off of Amazon. Nicely packaged set. Since the screw head was completely rounded out I didn't bother with one of the drill bits for prepping. I used a hand bit driver not a power driver or drill. And it worked just as advertised. Don't know about the long term quality. But there ya go.

-AJ