brake rotor bolt stripped

bonegirl said:

I slightly stripped the last bolt to remove the rotor. I don't want to make it any worse than it is. Does anyone have ANY advice on getting this off without further damage?

Are you still trying to get the last bolt out? If so, using a quality tool will help here, but you may be past the point of no return. Use a 6 point socket if you had been using a 12 point socket, and use more leverage from a longer wrench if you can.
If it's already out, then line the parts up carefully before you put them back together and go slowly. You can go to Sears and get a thread chaser, that will clean up the threads if you're worried.

I'm assuming you've stripped the head of the bolt, correct?

Most I've seen are torx bits, you weren't trying to use a phillips screwdriver or something similar were you?

if no threads are left you may have to cut a slot across it and use a plain old flat screwdriver... this could be tough if it's really tight. Try some penetrating oil overnight.

If it gets really ugly you might have to drill it out.

hedgehog said:

I'm assuming you've stripped the head of the bolt, correct?

Most I've seen are torx bits, you weren't trying to use a phillips screwdriver or something similar were you?

if no threads are left you may have to cut a slot across it and use a plain old flat screwdriver... this could be tough if it's really tight. Try some penetrating oil overnight.

If it gets really ugly you might have to drill it out.

I used a T25 torx driver and it is just beginning to spin in there. Damn the bugger is tight! Obviously torqued by a dude.

bonegirl said:

I used a T25 torx driver and it is just beginning to spin in there. Damn the bugger is tight! Obviously torqued by a dude.

If the head of the nut is stripped, then you can use a larger size driver and a ball peen hammer to get the old bolt out. Line up the next sized driver so it's square in the hole, drive it in with the hammer (use safety glasses) and spin out the old bolt.

I got it out. The secret? Heated it with a lighter and twisted the rotor back & forth. Voila!

I would suggest that you use some anti-seize lubricant on steel bolts that are screwed into aluminum. Since the different metals have different expansion rates, the fit or torque required to remove bolt can be greater than the amount of torque used to install bolt originally.