I have to take my clutch cover off to replace the swing arm bushings & the bolts will not come out . The bolts just keep spinning but will not thread out . I am getting ready to cut or drill out the head of the bolts .Do anyone have any ideas or comments please let me know. Is this a common thing ? Anyone else ever run across this .I am concerned about damaging the plastic cover.



1995 425 magnum 4x4

thanks

 

Try pulling out on the cover while turning the screws...or have someone else pull on the cover to try and get the screws to catch...

 

What is happening is the threaded inserts in the back cover are turnning.Try to get some vise grips on the insert to hold it and try to pry out a little on the outer cover(not hard enough to warp it))When you get them ouut you may have to replace them with nuts and bolts.

 

if you can take a very small drill bit and drill into the brass not the bolt and then you will be able to get them out..
Use penetrating oil on the back of the bolt first to release it if it is corroded or seized..

 

If you take a drill with the proper tip on it that will fit the screws, older models had philips heads, newer have hex, and spin the clutch cover screw at high speed for a short period of time, it will heat up the insert, and "re-weld" it to the rear cover. This will also expand the insert, hopefully letting the screw come loose. Let the insert cool berfore trying to remove the screw. I have done this several times with sucess. If you heat it up too much, the insert will just pop out, and you can CA (Super-glue) it back in. It takes a little practice, but it works well. Good luck.