Help Please! 8.8" Axle 8mm Bolt

[spiff]

I am hoping I can get some solemn advice from my fellow Mustang friends. I was in the process of replacing my rear outer axle seals on my 2001 GT. I got to the point where I was to remove the 8mm bolt in order to remove the pin to release the c-clips and subsequently the axles. However - Despite my best efforts, I had the box end of an 8mm wrench on the bolt and the axles barred by a helper to avoid rotation, but the wrench slipped - and rounded the bolt slightly.

I started to panic at this point - this seems to be the crucial link to the differential, so I do not want to destroy it. I could not find a socket to fit initially, however I found one that fits, somewhat decently with an extension and adapter to clear the bearing cap on the passenger side. It still feels a bit loose - well to tell the truth, evert 8mm I tried felt a bit sloppy. With my helper long gone, I took a 19mm wrench and barred the ring bolts so the ring will not spin, and tried to put a slight amount of torque on the 8mm bolt. It still seemed to slip and round it a tad bit more.

I am getting to the point where I am not sure what to do next. Has anyone had difficulty removing this bolt before? Please let me know how you did this. Also, if I do completely round it off and destroy it, what should my next step be? If it is unrecoverable, I honestly don't see how to salvage the differential. However, I am an amateur with dealing with them.

Thanks for your patience to read this, I also apologize in advance if this has been covered already - but I did search to no avail.

Thanks

Alex

 

[spiff]

Close to breaking out the welder!

 

[wmburns]

That bolt can be a PIA to remove. The red lock tight does hold it tight.

FWIIW, I use a SAE impact socket to remove the pin. A metric socket never seemed to fit as well as an SAE socket does. An impact socket won't break like a thin wall socket may.

I'm not sure what to recommend now that some "rounded" off. The area is tight and limits the tools that might otherwise be used.

 

[Rick 91GT]

If its really rounded off Sears/Craftsman sells a bolt removal socket that has teeth to grab the rounded off portion they work very well.

 

[Jinx]

If you have a welder, I've heard stories of people welding their socket to the stripped bolthead. I would only suggest this as a last resort as you will probably have to replace both the bolt and the socket once removed.