Cummins 6BT 5.9L-M starter removal

[DLECF]

Two different diesel mechanics have attempted to remove the starter. They found that the heads of the 3 bolts that secure the stater to the engine block were stripped by a previous installer. Two of the bolts have been removed but they have been unable to remove the one next to the engine even after dismantling the starter. They have presented me with the following options:
1. Attempt to cut the starter off of the engine
2. Remove the engine from the vessel, if option #1 is not successful
I would appreciate opinions from CF members.
Thanks

[jimbunyard]

Find another mechanic.


If the bolt shown is the final one, either cut it with a hacksaw blade with tape wrapped around one end (or you can get one of these ) and concentrate on removing the cut-off bolt after the starter is out of the way.

Conversely, you could try and rig some type of prying device (chisel, screwdriver, small prybar or lady's slipper) in the joint between the starter and the F/W housing to put tension on the bolt whilst someone else is turning it.

[DLECF]

Pictures of starter bolt

[jimbunyard]

Have you tried these?



They work pretty well if you can get them around the head of the bolt; if you have to drive it on, so much the better. If it is a tight fit on the outside, they can sometimes be ground enough to allow them onto the stripped head without weakening them so much they split when torque is applied.

[GordMay]

Jim: Who makes those stripped bolt removers?

[jimbunyard]

Irwin, Craftsman, Hanson... Auto parts stores have the cheaper brands (which work pretty good). Hate to advertise them, but Amazon's probably the easiest place to find the higher quality ones.

[donradcliffe]

Another option is to weld a small bar to the top of the bolt and use that to get the bolt loose.