How to remove a frozen axle pinch bolt on the forks.

[John Schmidt]

It's on the trike I bought, on the right side. My son-in-law and I worked most of the afternoon and got 3 of the 4 out but the outer one on the right side won't budge and is now rounded out as well. We were able to get the axle out but wasn't easy. We then pulled the better wheel/tire off the old bike to enable mounting the front wheel/tire from the trike on it. Since I was the last one to work on the front of my bike, we had the switch done on the old bike in about 20 minutes. After torquing the axle bolt I was then able to let the bike down off the jack. When I tried the large allen socket for the trike axle, I found the last jerk had beat the axle in place so the outer edges of the allen hole in the axle were all peened over. Out came the dremel...what an idiot. The axle nut was way overtorqued as were all the caliper bolts which should have been at 22 ft. lbs. and the pinch bolts. I had to use a breaker bar on everything and there was no sign of anti seize anywhere. Whoeve worked on it when replacing the tire and brake pads should have all his tools taken away from him, but only after beating him senseless with them. 

I'm now facing the taks of trying to somehow breaking the one axle pinch bolt loose so I can remove it. I'm going to order new ones for both the trike and bike but for now I just need to get the one out. I've tried everything in my shop with no luck, at the moment I have the lower part of that fork turned up and some PB Blaster soaking over night. I'm open to suggestions on my next step, the bolt remover kit I have won't cut it.

[Valker]

JBWeld the right size hex into the screwed up bolt. Let it cure the stated time (they have JB Quik Weld) then remove it.

[Chrisj CMA]

I think I would try penetrating oil heat and easy out type extraction

[John Schmidt]

I have a Bernzomatic torch, an easy out didn't work but only tried it without predrilling a deeper hole for it. Debating about going to a local Menards, they have loads of tools, many specialized such as easy outs. Since the wheel is out I turned the fork lower so the threaded side is facing up and filled it with penetrating oil. Before I hit the sack I think I'll go mix up some JB Weld and fill the head with the next size allen socket in place. Then maybe after it sets up solid I can hit it with a torch and hope it works. The new bolts are going in with some anti-seize. Whoever did the tire and pad change was a fool. One of the caliper bolts had 3 washers on it so when I got it out I compared it to the others. It's too long and the jerk was either too lazy to cut to length or get a new one the right length...he just added washers. 

[CoreyP]

I think I would try penetrating oil heat and easy out type extraction

Yep I second that. You just need something that will give you enough torque on the easy out. An electric hammer drill will usually do it but you may need a full on air one. Depends how much torque they put on them?

[Gryphon Rider]

Here's what I did on my front brake pins.  I would do the same for pinch bolts:

http://www.valkyrieforum.com/bbs/index.php/topic,27923.0.html

[Daniel Meyer]

Also put the other pinch bolt back in and tighten...it takes some of the "pressure" off the one that's stuck.

[John Schmidt]

Also put the other pinch bolt back in and tighten...it takes some of the "pressure" off the one that's stuck.

Daniel...never thought of that but worth a try. I'm going to see how far in I can get the axle and if far enough to allow putting the wheel in place I'll do that. Then let the trike down off the jack so the wheel supports the fork some. I don't like the idea of smacking the end of it with no support or stabilizing factor on it.

[Mooskee]

I'm probably preachin to the choir, but easy outs are brittle. It you break it off in there with an impact driver it will be a long day to fix it. Great Idea putting the other pinch bolt in. Hopefully heat and JB weld will get it.

[luftkoph]

Take it to a machine shop, it will probably be a piece of cake for them

[John Schmidt]

JB Weld was useless in this case, just shattered so cleaned it out to start over. I tried Daniel's suggestion of inserting the adjacent bolt to remove some tension. That alone didn't do the job so next applied my heat gun for about 30 min. and dug out my Hanson Straight Flute Extractor Set. Hadn't found or used it since moving here last year but came in handy. I had already left it soaking with PB Blaster penetrating oil over night. I first tried inserting the axle to help stablize the fork when tapping the extractor into the head. That's when I discovered the forks aren't even...right side lower by about 1/32" making it difficult to run the axle all the way through. My first thought was ..."anything else going to be screwed up?"

Once all the stars were aligned; heated fork in the immediate area, axle partially inserted, adjacent bolt in place, extractor tapped into bolt head....deep breath and applied some action with a crescent wrench. No movement so tapped it in a fraction farther and with a bit of a grunt it broke loose. Was probably a combination of everything that broke it loose. What a PITA, if that never happens again it will be too soon.    It's 26 deg. so once I got the wheel in place I left it alone for now. I had to use a bottle jack to raise the right fork a bit to insert the axle but did get the wheel in place. Tomorrow temp is to be about the same but Wed. predicted in the 30's which my IR space heaters will do fine in raising the temp in the garage. Then I'll address the uneven fork issue.

This was almost enough to make you forget what you learned in Sunday School as a kid!  

[Mooskee]

My son was in the middle of nowhere in his truck when the water pump went out requiring an out of town repair. The old mechanic raised up from the engine bay and said, "You can be a preacher or a mechanic. You can't be both because this poop will make you lose your religion."

[The emperor has no clothes]

My son was in the middle of nowhere in his truck when the water pump went out requiring an out of town repair. The old mechanic crawled raised up from the engine bay and said, "You and be a preacher or a mechanic. You cant be both because this poop will make you lose your religion."

[da prez]

Use a blunt punch that fits inside the allen bolt. Hit it hard several times. Try to work in some penetrating oil. Hit it a few more times. They will usually come loose.

                da prez