Stripped feed pump cover screws while disassembling injection pump..suggestions?

[captainpartytime]

While disassembling my injection pump I stripped the two #2 phillips head screws that hold the feed pump cover to the feed pump. Any ideas on how I can get myself out of this mess??? I'm contemplating JB welding two #2 phillips bits to the two screws and then hopefully attaching a driver to them and removing them. Here's where I'm at (except my screws are still in place)... Any suggestions???

[Rabbit TD]

I  can't tell how bad they they are stripped but an impact screwdriver with the adapters needed are what works best down in a hole like that.  If you can't get an impact screwdriver get a screwdriver that fits right, {#2} and try tapping it into the center to get the mess straightened up the best you can and then with the pump supported in a vise tap on the screwdriver with a hammer as you try to twist.   The best thing is to use an impact type first, I thought about what you are going through right now when I first saw those screws in the first pump I took apart and what a mess it would be if they got stripped.  Luckily I happened to have an impact and adapted it down to 1/4 drive with a #2 bit and it worked fine.  Other than that I don't know what else would work short of the machine shop

[fatmobile]

Stick something flat on top of the screw and hammer on it.
 That will smash the head back down, then pound your screwdriver tip into the smashed top.
That will reshape the top and help break it loose with all the hammering.

[anto]

I stripped one of mine.
I ended up drilling it out, being very careful not to mark the inside of the pump...

[92EcoDiesel Jetta]

How about trying an impact screwdriver, the type that you hit with a hammer? If it is not too badly stripped, it may just work. You may have to fashion a long extention so the bit sits square on the phillips head.

[Quantum TD]

I stripped one of mine.
I ended up drilling it out, being very careful not to mark the inside of the pump...

That's what I'd suggest. You'll need a really long drill bit about the same diameter of the screw head (perhaps a bit smaller), and carefully drill it out. Once the tension is off the screws when you drill out the heads, then the shafts should come out pretty easily.

For future reference (should you try this again), get a really long screwdriver with a non-mangled tip, and hammer it into the phillips heads of the screws. That should break them free enough to unscrew.

[captainpartytime]

For future reference (should you try this again), get a really long screwdriver with a non-mangled tip, and hammer it into the phillips heads of the screws. That should break them free enough to unscrew.

Yes, this first rebuild was an n/a pump that I was using for practice before I rebuilt my TD pump. I did use a brand new screwdriver but will definitely be hammering it down into the screw head this time...thanks for the tip!!!

[92EcoDiesel Jetta]

For future reference (should you try this again), get a really long screwdriver with a non-mangled tip, and hammer it into the phillips heads of the screws. That should break them free enough to unscrew.

Yes, this first rebuild was an n/a pump that I was using for practice before I rebuilt my TD pump. I did use a brand new screwdriver but will definitely be hammering it down into the screw head this time...thanks for the tip!!!

I do not see how hammering down a regular screwdriver into the screw head will help. What you need is an impact screw driver that turns as you hammer on it in one motion.

[92EcoDiesel Jetta]

Like these:

http://images.google.com/images?client=firefox-a&rls=org.mozilla%3Aen-US%3Aofficial&hl=en&q=impact+screw+driver&btnG=Search+Images&gbv=2&aq=f&oq=&aqi=

[anto]

I stripped one of mine.
I ended up drilling it out, being very careful not to mark the inside of the pump...

That's what I'd suggest. You'll need a really long drill bit about the same diameter of the screw head (perhaps a bit smaller), and carefully drill it out. Once the tension is off the screws when you drill out the heads, then the shafts should come out pretty easily.

For future reference (should you try this again), get a really long screwdriver with a non-mangled tip, and hammer it into the phillips heads of the screws. That should break them free enough to unscrew.

The reason i rounded the heads on mine was due to the torx bit i was using was in its holder which meant it sat at an angle to the screw head.
I was also stupid as i should have known when doing it that it was too tight but i carried on regardless like an impatient idiot.

[92EcoDiesel Jetta]

I am getting confused, the OP said #2 phillips, you say it's torx. No matter the fastener, the driver bit has to sit square or you risk stripping it.

[anto]

Well my bosch pump was out of a citroen xsara so it may be different.
Mine was torx but it makes no difference!

[burn_your_money]

Older pumps are philips, newer are torx.

Hammering it has the same effect as hammering a stubburn bolt. It helps knock it loose.

[captainpartytime]

Update...these #2 phillips screw heads were stripped badly. I took a wild shot in the dark and hammered down on the screw head with a long phillips extension bit and sure enough, they broke free fairly easily! Thanks for the tip! I was about to drill them out and said, "what the heck, I'll give the hammering technique a shot". I'm AMAZED at how well it worked. The metal in those screws seems VERY soft. I don't know if it was because of age but they sure felt soft to me. Take Andrew's advice...DO NOT drill out the screw heads!!! You will never retrieve the rest of the screw from the pump body. There's no way to get in there to grab what little nub is left. This should only be used as a last resort!

[rabbitman]

I know you got 'em out but I've used a torx bit to get rounded phillips screws out before, just pound it in good and hard and if it sinks in nice it "usually" works fine.