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Old August 11th, 2018, 11:36 PM   #1
DannoXYZ
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stripped brake pad pins?

I go to put new pads in and founded PO had gifted me one stripped-out pin per caliper. Allen-key just spins in rounded-out hole.

Any suggestions for removal?

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Old August 12th, 2018, 06:08 AM   #2
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Can you post a photo of it?
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Old August 12th, 2018, 07:09 AM   #3
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Start with penetrating oil and patience. If the caliper is off the bike and drained dry, you might also use some heat but be careful. You don't want to melt sensitive pieces (e.g. piston seals) or start a fire.

If the hole is shot, you might try getting a Torx bit that's slightly larger than the hole. Pound it in good and solid with a hammer so you have a positive interference fit (you'll destroy the bit doing this, BTW). Then use a hand-held impact driver with socket on the bit to break the bolt/pin loose.

What this amounts to is that you're putting a hex-headed pin on the end of your stripped fastener, which gives you something to grab. Socket goes over the bit and into the impact driver, whack whack whack and if all goes well it comes loose.

I've done this successfully when I stripped out an overtightened bodywork fastener on my then-new GSX-R. The usual method (heat) was a no-go because it would have melted the body panel.

The trick is that you only really have one shot at this. If you strip out the hole with the Torx bit, you're going to be drilling the pin out. So be patient and use that impact driver, giving it solid, deliberate whacks (a dead-blow hammer is the tool of choice for this).
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Old August 12th, 2018, 07:18 AM   #4
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You can also try a stripped bolt removal tool like this one. https://www.googleadservices.com/pag...Qwg8IKg&adurl=
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Old August 12th, 2018, 09:40 AM   #5
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I have no idea what you are talking about but maybe this can help!

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https://www.hagerty.com/articles-vid...18_HagertyNews
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Old August 12th, 2018, 01:22 PM   #6
DannoXYZ
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Thanks for ideas!!! Was wondering if anyone else had overcome this issue to save me some time.

I've got replacement pins in yesterday! Now just matter of getting stripped ones out. Two I did get out was bare without any threadlocker, so I suspect case of anodic corrosion. I'll use teflon-tape on those when re-installing to keep them insulated.



Using this thread as guide, Stripped Allen Head, I drilled down shank of pin and use traditional screw extractors.



>SNAP< now I've got chunk of hardened steel down in hole!

I used better set of extractors on other stripped one and it came right out!



Gonna shove other in mill and grind off broken extractor and use better extractors to remove it.
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Old August 13th, 2018, 03:40 AM   #7
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I've had the exact same thing happen with traditional screw extractors, which is why I went with the Torx bit hack. If it had failed, I could still try a traditional extractor.

The problem with the traditional extractor is precisely what happened to you. Now that it's snapped off, you're cooked. No second chance because the pin is now completely mangled.

The extractors on the bottom look great... never seen those before. Same basic idea...
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Old August 13th, 2018, 09:58 AM   #8
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Quote:
Originally Posted by DannoXYZ View Post
I'll use teflon-tape on those when re-installing to keep them insulated.
Blue threadlocker (I like the gel) should keep it from corroding and loosening as well.

Not sure I'd use pipe tape on them.
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