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2005 FIesta - Replacing front brake discs seized rounded bolts - JALOPYS

I was just wondering if its possible to renew the discs without removing the brake caliper cage as last year i could not get the bottom bolt losse so i just split the caliper by removing the two allen key bolts and replaced the pads that way and as dont have acces to any heat to warm the seized bolts up any advice would be welcome.

2005 FIesta - Replacing front brake discs seized rounded bolts - gordonbennet

Don't like splitting calipers open, cage has got to come off for the discs to be renewed.

The bolts have rounded because a poor socket or spanner, 12 sided, has been used.

Invest in a set of impact sockets, 6 sided, very tough, they usually get all but the must stubborn bolts out, soaking the bolts in Plus Gas for a few days before removal will help.

Heat could still be the only answer, you could pop into a local garage and just ask the chap to pop some heat on and loosen the bolt for you for a drink, requires care though lots of rubber seals etc in the vicinity.

Another complete hub/leg assembly from a handy breaker might be another solution if you get no joy, probably easier than drilling out and retapping if the bolt won't shift.

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2005 FIesta - Replacing front brake discs seized rounded bolts - madf

Angle grinder used carefully...

2005 FIesta - Replacing front brake discs seized rounded bolts - HensTeeth

gb's advice is sound, as ever. If the impact socket and plusgas approach doesn't work, one other tool I've found works well, if you can obtain one the right size, is a special Irwin Bolt Grip socket. I think there are other brands available with similar claims, but I've only personal experience of these.

I used a couple of sizes on various parts of the exhaust manifold/downpipe on an old Renault Megane, where the bolt heads had become cylindrical. Downside is that the bolt/nut head will be all but destroyed, but sounds like you might not care too much about that at this stage.

I wasn't expecting much, after very bad past experience with stud extractor tools, but the bolts just wound out like their heads were new.

Oh - and if you've enough access - don't be frightened to give the heads of the stuck bolts a good whack with a hammer - that simple action can crack the rust which is holding the the bolt fast. Just be careful you don't destroy anything else in the vicinity, especially yourself...

2005 FIesta - Replacing front brake discs seized rounded bolts - MrEckerslikefromRamsbottom

Thanks for the info on the Irwin tools. I've just had a look on e-Bay and one of the 5-piece sets does include a 13mm tool which will fit the Fiesta caliper bolts.

I have a small set of impact sockets which I bought many years ago. There's no maker's name on either box or sockets. The sizes up to 14mm are chamfered down at the business end making them a sort of 'blunt bullet' shape, so that the 13mm one is ideal for the tight access into the caliper bolts, and it's what I use when changing the discs and pads. The bottom bolt is tight to get at if the car is just jacked up, but would be easier on a garage lift. I would be tempted to use the impact socket on the end of my old impact driver and see if it would fit in to this damaged bolt, and then give it some wellie with a lump hammer. Then again, the Irwin tool sounds easier!

2005 FIesta - Replacing front brake discs seized rounded bolts - gordonbennet

Thanks for the info on the Irwin tools. I've just had a look on e-Bay and one of the 5-piece sets does include a 13mm tool which will fit the Fiesta caliper bolts.

Yes my thanks too, never used them but there have been times when they would have saved me a heap of grief and skinned knuckles, and anyone in earshot from my reaction.

Removing the gearbox from a Toyota Supra many years ago put me onto impact sockets, i'd struggled with combi spanners and normal sockets on the top bell housing bolt that would not shift, 14mm can still see it but very shallow head, almost rounded off and i'm scratching me bonce...someone lent me a 14mm impact 6 sider...i slid underneath and with about 3ft of extensions and a universal i got the socket on the bolt, click, undone no probs.

Wouldn't be without them now, not only do they not slip but being heavy if you use an impact extension and an old click type torque wrench as your ratchet the amount of control and feel you have over the moment of release of the stuck bolt is superb and satisfying and ultimately less painful, none of that slight twist (almost like play) you get with lighter extensions and sockets the they suddenly give and then you curse as yet another knuckle bites the dust.