Stripped out 8mm Allen Cap Screw on A/C Compressor! - Troubleshooting - VWDiesel.net The IDI, TDI, and mTDI source.

• Stripped out 8mm Allen Cap Screw on A/C Compressor! by GIDDY_UP_GO on 14 Aug, 2009 19:43
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  I am trying to loosen up the AC compressor on my 1986 VW Golf Diesel N/A so that I can replace the belts. Well all was going good until I tried to loosen the aluminum cap screw that is at the back of the compressor directly under the IP on the right hand side as you are standing in front of car.
  
  I believe this is an 8mm Allen cap screw made out of aluminum. Don't know if it is stock, or someone rigged it up, but the inside is all buggered up and I cannot get a bite on it, the inside is all rounded out. Any suggestions would be appreciated. Also, if I ever get this out, what type of bolt should I replace it with??
  
  Here are a couple pics, not good quality, but you can see what I mean:
  
  
  
  
  
  
  
  
  
  
  
• #1 by Dakotakid on 14 Aug, 2009 20:42
• And put the other bolt back in and somewhat tighten it to help support the compressor while you work on the right side. These aluminum "loops" with the bolt hole break off rather easily. They crack out when the bolt goes through.
  Do not get angry and try to wiggle the compressor back and forth while working....the above will happen also.
  
  I buy replacement bolts at ACE hardware for not much money. I will buy like 10 at a time to have around so I can toss the old one if it begins to be even remotely rounded.
• #2 by GIDDY_UP_GO on 15 Aug, 2009 07:10
• Thanks for the replies. I actually went to Sears and purchased a bolt extractor for $9. It took me all of 5 minutes to remove this dreaded bolt!
  
  
  Now for my next dilema.....
  
  Is there suppose to be 4 bolts that hold the A/C unit onto the bracket? I had only the one bolt at the back of the compressor under the IP which was a 8mm Allen cap screw. Then I have two other bolts and nuts at the front of the car that you loosen to slide the compresser on the bracket.
  
  Now surely I am suppose to have a 4th bolt on the pulley side of the compressor, or is it a stud that the compressor swivels on?
  
  Thanks for all the help!!!!
• #3 by Quantum TD on 15 Aug, 2009 10:00
• There should be 2 8mm allen bolts that hold the compressor to the bracket. The one on the belt side of the compressor is a mirror image of the nasty that you just pulled out. Look for a broken bolt shaft stuck in the alternator bracket on the belt-side of the bracket. Pray that you don't find one. If you do, you'll want/need to extract the broken bolt somehow.
  
  On the slide part of the bracket (up front), there should be 1 carriage-bolt on the belt side with a 13mm head nut on it. On the inside (trans side) of the bracket, there should be an adjustment loop-bolt with a long 13mm bolt that runs vertically into an adjustment nut which connects to the compressor and it locked in place with a 13mm head nut.
  
  Looking at your pics, it appears that you have the right parts. You'll just have to see if you have a broken bolt in the cast-iron AC bracket.
  
  If you need replacement bolts, I have some of the correct ones, or go to your local bolt store and get some grade 8 metric allen bolts. There is a risk there though: if the bolts break in the cast iron bracket with grade 8 bolts, you will NEVER get them out. So, use some neverseize.
  
  
• #4 by GIDDY_UP_GO on 15 Aug, 2009 10:14
• Thx for the reply, I just got back from Napa with some replacement bolts. I am praying that the belt side 8mm bolt is just missing and not broken off in the bracket!
  
  I am glad to see that I am not the only one that has went thru this process!
  
  That bolt extractor that I purchased from Sears was a lifesaver, I will post pics and the product number as soon as I get the car back together.
  
• #5 by fatmobile on 15 Aug, 2009 20:16
• If there wasn't a bunch of bolts missing/broken, you could have just removed the crank pully, slid the new belt into place and bolted the crank pully back on.
• #6 by GIDDY_UP_GO on 01 Sep, 2009 17:12
• As promised, here is the picture of the Bolt Extractor that I purchased from Sears for $9.99. This item turned 2 days of frustration and bloody knuckles into 2 minutes of effortless removal of a pain in the butt cap screw!
  
  
  
  
  Here is a link to the product at Sears: http://www.sears.com/shc/s/p_10153_12605_00952061000P?keyword=952061&sLevel=0
  
  After removing the cap screw, I went to Napa and purchased two replacement Hex bolts. I don't remember the actual size, but here is a few pics of them holding the A/C onto the bracket.
  
  
  
  
  
  
  
  
  
  
  And now for the dreaded cap screw that gave me such a pain!
  
  
  
  
  And a couple pics of the half-azzed shop. Note how I have just about every tool I own strewn across the garage floor! (LOL, I would never make it as a mechanic!)
  
  
  Note: The fan on the rad support is to cool my frustrated azz off, I was sweating up a storm!