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  1. #1
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    Dec 2018
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    Oldest problem in the book...

    I am doing the timing belt, water pump, tensioner, drive belt, etc. on my daughter's 2006 Passat 2.0T.

    I have spent almost 2 full days trying to get all six of the crank pulley bolts out. The first three were reasonable, the fourth was difficult. The fifth was a miracle. There is no corrosion, the threads seems perfect, but the bolt heads seem to be buried in the pulley surface. Someone over tightened them?

    I am still left with one bolt and have tried everything common sense, plus most of what is on the internet. I even tried welding a second bolt onto the pulley bolt but the recessed location plus the very close proximity to the gear bolt in the center has made good weld penetration impossible.

    If any of you professionals out there have a method to offer, I am all ears!

    6mm hex center is stripped out
    tried an outside edge bolt extractor but it is now rounded, no more edges to bite with
    tried heating with a torch then allowing to cool

    I have not drilled out the center and tried an inner extractor simply because I have had bad luck with them in the past



    PS - I'm glad I don't do this for a living or I would have no money to eat!
    Last edited by Uwe; 07-28-2019 at 07:02 PM. Reason: Added image in-line

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