KDSS Allen Screw Jam

[Mooterman]

Somehow the head of the allen wrench snapped off when trying the loosen the KDSS valves and is completely jammed in the allen screw. I tried drilling it out with a cobalt bit but it barely scratched the surface. Does anyone have any other ideas on how to get this out? Thanks!

 

[kcjaz]

I would have tried drill bit first too. Maybe Dremel with very small grinding bit? Obviously you don't want to damage the hex flat side walls. Dental picks? Sorry, not much help here.

 

[CharlieS]

Most of us end up welding a nut to the bolt at that point.

 

[Fisher23]

I would first try a small punch or chisel and a hammer. Try tapping it and see if it comes loose. It looks like it needs to turn a little clock wise to come loose, I would tape it so it turns.
Then maybe a bolt and JB weld if that failed.

 

[Weedhopper]

This stuff has saved my butt many times. It’s a lube plus it cools the metal so it contracts a bit. Not sure how to pull the part out. If you were twisting the part is probably jammed in there.

 

[CharlieS]

I've been exactly where the OP is with my KDSS shutter valve screw. If it broke under torque while trying to open it, my guess is that it is probably not coming out. But I wish you luck. Maybe it'll go better for you than it did for me.

 

[Karbon]

If you still want to try the drilling route, an option is to go with a harder carbide-tipped bit such as this.

 

[grinchy]

I’d suggest welding like others have. Between the heat of welding and the nice nut to put a wrench on, it’ll be loose in no time and you can get your suspension update done

 

[RET2]

I’d suggest welding like others have. Between the heat of welding and the nice nut to put a wrench on, it’ll be loose in no time and you can get your suspension update done

Couple of caveats, don't forget the O ring that is in there and no more than 3 turns out.

 

[Mooterman]

Thanks for all of the suggestions. Will try a few today. Unfortunately, my welding capabilities are exactly zero so would have to find a pro for that. I was just attempting to correct a 5/8" lean that was bothering my OCD. The first valve opened fine. Probably the ultimate solution is to drive up to Slee and have a new suspension installed. Surely the guy in the shop could fix it!

 

[RET2]

Thanks for all of the suggestions. Will try a few today. Unfortunately, my welding capabilities are exactly zero so would have to find a pro for that. I was just attempting to correct a 5/8" lean that was bothering my OCD. The first valve opened fine. Probably the ultimate solution is to drive up to Slee and have a new suspension installed. Surely the guy in the shop could fix it!

I have found the lean factor is migratory, my vehicle is seldom if ever perfectly level. Spirited driving or passive adjustment via floor based parking spacers can help though.