[xj40] Torx heads on transmission filter bolts stripped

XJ40
1

Hi,
Any listers have you any proven techniques for removing torx bolts with the
torx head stripped. In particular the three torx head bolts holding the
transmission filter on my XJ40 90MY. Drained the transmission fluid, took
the transmission pan off and have failed miserably in getting the threee
filter bolts out. The torx heads are stripped. I’ve tried using a slightly
oversize to correct but alas no avail. And, the torx set are Snap-on quality
so it is not really the tools…so i’m not blaming them…I suspect more me
and the hobbits that have been at it previously. Put it all back together
and pretend you didn’t touch it is not really an option…would be if it
were the brother-in-laws car.

And, if you have not done this before, ie, changing the transmission filter
it is not a pretty place to spend a lot of time under as transmission fluid
paints the garage floor! (And, if you have had the car running for a bit
with the aircon on, the damn aircon drain just adds to your pleasure by
dripping you with water:-)…like some form of torture really.)

Any advice. Thanks in advance…

Garry
XJ40 Sovereign 90MY
223000km

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2

Let’s hope the ape didn’t tighten any of the other screws when he did that,
they are just supposed to be tightened a little. Too much torque on those
and you warp the valve body or strip threads.

Have you tried a vice-grip judiciously clamped onto the outside of the
screw? Of course, this wouldn’t work if the one in the center that’s
recessed is stuck.

Dave Lokensgard
'96 XJR
'90 Vanden Plas Majestic (DAVZCAT)
'55 XK140 OTS
Poway, California

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3

Gary,

I had the same problem with my XJ40 the first time I came to change the
transmission filter.

Looking at the options, I didn’t want to damage the filter itself in case
the torx bolts eventually refused to shift and I had to abandon any hope of
changing it. Cutting away the filter to take the tension off the bolts would
probably have worked but there’s no way back if the bolts are completely
seized or the threads in the aluminium transmission block are stripped. If
they weren’t going to slacken, I wanted to be able to leave the filter
undamaged and correctly fitted.

I used a miniature power tool with a cutter disk to put a straight slot
across the torx heads and then loosened them with an impact driver. The two
on the edge are easily accessible with a standard power tool but the
recessed one in the middle needs a small diameter disk to avoid damaging the
filter.

Jaguar dealer didn’t have replacement bolts in stock and had to order them
from the factory. Worth a call before you start. Only takes a couple of days
to get them in the UK but your e-Mail address suggests it might take a bit
longer.

Graham Gardner
1996 XJ 3.2 Sport

Date: Sun, 18 Jan 2004 14:57:39 +1100
From: “IIT Training” garry@iit-training.com.au
Subject: [xj40] Torx heads on transmission filter bolts stripped

Hi,
Any listers have you any proven techniques for removing torx bolts with the
torx head stripped. In particular the three torx head bolts holding the
transmission filter on my XJ40 90MY. Drained the transmission fluid, took
the transmission pan off and have failed miserably in getting the threee
filter bolts out. The torx heads are stripped. I’ve tried using a slightly
oversize to correct but alas no avail. And, the torx set are Snap-on
quality
so it is not really the tools…so i’m not blaming them…I suspect more
me
and the hobbits that have been at it previously. Put it all back together
and pretend you didn’t touch it is not really an option…would be if it
were the brother-in-laws car.

And, if you have not done this before, ie, changing the transmission filter
it is not a pretty place to spend a lot of time under as transmission fluid
paints the garage floor! (And, if you have had the car running for a bit
with the aircon on, the damn aircon drain just adds to your pleasure by
dripping you with water:-)…like some form of torture really.)

Any advice. Thanks in advance…

Garry
XJ40 Sovereign 90MY

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

4

Garry,

Any listers have you any proven techniques for removing torx bolts with
the
torx head stripped. In particular the three torx head bolts holding the

Garry
XJ40 Sovereign 90MY
223000km

As Graham Gardner has already stated, cutting a slot in the head so you can
use a straight screwdriver is often an option. Another might be to use a
so-called EZ-out (screw extractor), since the botched Torx head bolt already
has a recessed ‘hole’. I’ve not had great success using EZ-outs on sheared
bolts (operator error I’m sure) but this might be a good application.

Mike Stone
Jet Black 1994 XJ6
107,xxx miles
Springfield, Missouri USA

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

5

Sometimes to make the EZ out work you have to drill a bit of a hole in
the center of the torx hole so it can bite. Sears is advertising a new
tool that is like an EZ out but shallower and they “guarantee” it will
work etc. Haven’t used it but planning on trying it on one torx head I
have that is damaged and wont come out on the sill so I can replace the
rubber gasket.

Jay 90 VDP Majestic

Mike Stone wrote:

Garry,

Any listers have you any proven techniques for removing torx bolts with

the

torx head stripped. In particular the three torx head bolts holding the

Garry
XJ40 Sovereign 90MY
223000km

As Graham Gardner has already stated, cutting a slot in the head so you can
use a straight screwdriver is often an option. Another might be to use a
so-called EZ-out (screw extractor), since the botched Torx head bolt already
has a recessed ‘hole’. I’ve not had great success using EZ-outs on sheared
bolts (operator error I’m sure) but this might be a good application.

Mike Stone
Jet Black 1994 XJ6
107,xxx miles
Springfield, Missouri USA

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !

Visit the Jag Lovers homepage at http://www.jag-lovers.org for exciting services and resources including Photo Albums, Event Diary / Calendar, On Line Books and more !