Guide on stuck screws on 90-94 fog lights?

[Itzallstock]

Does anybody have a guide or a solution to getting stripped or stuck fog lights screws out? I am talking about the 2 screws that hold in the front lens. I have 2 stripped screws and have been covering the other 2 good stuck screws with rust remover for about 2 days. Can get anything to move. Can i drill these out?
-Thanks
Brn

 

[ClevSilverEclip]

REF: http://www.dsmtuners.com/forums/showthread.php?t=148518&highlight=extractor

I'm currently in the process of this extremely, extremely frustrating removal - trying to upgrade my stock fogs/drivings to 50W 885 bulbs and to re-construct the front lens with a projector unit.

You've already tried "soaking" in chemical "breakers," so the next step would be to try using a Dremel or other rotary cutting tool to cut a notch in the stripped screw head so you can use a large straight screwdriver to back out the screw.

Failing that, you can hop down to your local hardware store for a screw extractor kit. It's essentially a reverse-thread tap. First you drill a pilot hole into the stripped head of the screw, then you wedge it in with the help of a hammer. Finally, you use it to back out the screw, now with the help of a bit handle.

Another option would be to drill out the screw heads, in which case the lens unit should just back right off.

I tried the extractor, but it didn't work -- probably bad technique on my part (I'm a biologist by trade and training) -- and am currently trying to drill out the heads. Problem here is that tried to put in too small an extractor, and managed to break off a drill bit in one of the screws, thus making it rather difficult for my current task of drilling off the screw head!

Best of luck!

-A

 

[Defiant]

You might try the Craftsman removers Bob Villa pimps on the TV. I'd not have tried the drill-and-grab EZ-Outs, for the reason you've proved.

Oh, and PB Blaster.

 

[ClevSilverEclip]

Defiant,

, lessons learned, right?

-A

 

[Spyder FX]

I second the craftsman kit, it works wonders on rusted, stripped screws.

 

[DROOPY209]

I have the exact same problem as well, and my screws seem to be rusted as well.

I tried to use a screwdriver to get the screw out but that didnt work so now I am goin to spray some PB blaster on it over a couple days and hopefully that will work. Im going to keep spraying it down for about 2 weeks until i run out of pb blaster and then imma warm it up with a heat gun and try again.

 

[Itzallstock]

PB wont work. I failed on that method. The dremel tool slot method also does not work. The metal is jsut too soft!

After a few hours last night I have it!

If your fog lights have stubbon screws simply follow these directions...

1. Try and get acsess to a drill press. They have really cheap ones out there so if you have been thinking about getting one, go for it. I almost put a bit through my hand last night.

2. Drill a "pilot" hole with a very small bit in each of the heads. Make sure you use thread cutting oil during the hole drilling procedue. It did wonders for me.

3. After you have pilot holes take a 1/4 bit and go again on each head.

4. Now take the next size bit up and drill again. Pause every few seconds and wipe out the hole with a paper towel. The thread cutting oil sticks to the metal shavings and makes it hard to see.

5. The screws are soft, becarful when you get toward the bottom of the head, you'll feel a big loss of resistance when you get through the head, STOP or else you'll go very quickly though the plastic........

6. There are 4 small plastic tabs that also hold the lens on. You need to pop those out by pushing on them with a small flat head screw driver. Then the lens with fall into your lap after you have removed the 4 tabs.

7. Almost done, you still have the stubs sticking out where you took the heads off. Try and grab them with a small pair of vice grips. I was able to get all but one off like that.

8. If vice grips failed use 1/4 bit and go the rest of the way, its takes forever but its the only way. I am thinking if you bought a really long 1/4 bit you could go backwards into the screw but i didnt have the time to mess with that.

Happy Screwing!

-Ben Witek