How to Pull Out a Stripped Bolt – Step-by-Step Guide

How to get bolt out that is stripped?

1. Use a Bolt Extractor Set

A bolt extractor is designed to grip stripped bolts and remove them. Start by drilling a small hole into the center of the stripped bolt using a drill bit slightly smaller than the extractor size. Insert the extractor into the hole and tap it gently with a hammer to secure it. Once seated, use a wrench or socket to turn the extractor counterclockwise, pulling the bolt out. Popular extractors include Easy-Out or Inland tools.

2. Apply Penetrating Oil and Impact Wrench

Loosen corrosion or rust by squirting penetrating oil (e.g., PB Blaster) around the bolt and let it soak for 10–15 minutes. Use an impact wrench set to reverse, applying short bursts of force. The vibrations can break the bond between the bolt and surrounding material. For stubborn cases, alternate between oiling and using the impact wrench repeatedly.

3. Cut and Remove with a Hacksaw

If the bolt head is intact, use a hacksaw to cut through the bolt below the head, creating a flat surface. Once cut, place a screwdriver or bolt extractor tool into the slot and tap it with a hammer to create leverage. Rotate the tool counterclockwise to unscrew the bolt. For deeper stripping, cut the bolt flush with the surface and proceed to the next method.

4. Drill Out the Bolt as a Last Resort

Drill the center of the stripped bolt using a drill bit slightly smaller than the bolt’s diameter. Once drilled, insert a step bit or spade bit to enlarge the hole, then use vice grips or pliers to grip the remaining metal and twist it out. Dispose of the damaged bolt and replace it with a new one. Wear safety goggles to protect against flying debris.

How to remove a bolt that is rounded off?

One effective method to remove a rounded-off bolt is by using a drill and left-cut tap. Start by drilling a hole into the center of the bolt, slightly smaller than the desired tap size. Next, insert a left-cut tap (reverse-threaded) into the drilled hole and turn it clockwise. The tap will cut threads into the bolt, allowing you to screw in a screw or bolt with standard threads to pull it out. This technique works best on softer metals like aluminum or steel.

Another approach involves using an impact driver or breaker bar with a socket that fits snugly over the damaged bolt head. Apply steady pressure while rotating the tool. For tougher cases, place a cheater tube over the handle to increase leverage, but be cautious to avoid breaking the bolt further. If the bolt is rusted, apply penetrating oil (e.g., WD-40) to loosen corrosion before attempting to turn it.

For more stubborn bolts, a bolt extractor kit is essential. These kits include spiral bits or internal-grip extractors. Insert the spiral bit into the bolt’s center hole and tap it lightly with a hammer. Once seated, use a wrench to turn the bit counterclockwise, gripping the bolt and pulling it out. Alternatively, use an internal-grip extractor by tapping it into the bolt’s head to create purchase, then turning it with a wrench.

If extraction isn’t possible, consider cutting the bolt off using a cutoff wheel or angle grinder. Secure the part with clamps, wear eye protection, and grind through the bolt head until it’s flush with the surface. Clean up any remaining threads with a thread-chasing tap or file, ensuring the area is smooth for future use. Always prioritize safety by wearing gloves and protective gear during these processes.

How to loosen a bolt that won't budge?

If a bolt refuses to loosen, it’s often due to rust, corrosion, or galling caused by moisture, heat, or prolonged use. To tackle this effectively, start by identifying the root cause and applying targeted solutions. Here are actionable steps to free stubborn bolts safely:

Use Penetrating Fluids and Let Them Soak

Apply penetrating oils like PB Blaster, WD-40, or Liquid Wrench directly to the bolt threads. Use a brush to spread the fluid into tight gaps. Let it soak for 15–30 minutes (or longer for severe rust) to break down corrosion. Repeat applications may be needed for deeply rusted bolts.

Reinforce Torque with Tools

Attach a socket wrench or open-ended wrench securely to the bolt head. Add a breaker bar or cheater tube to the wrench handle for extra leverage, but avoid over-tightening grips to prevent stripping. For hex bolts, try tapping the wrench with a hammer while turning it to jar loose corrosion.

Heat Expansion for Seized Bolts

If fluids fail, apply localized heat using a propane torch to expand the metal, creating microscopic gaps in rust. Focus heat on the bolt for 2–3 minutes, then immediately try loosening it with tools. Exercise caution: avoid overheating alloy materials or nearby flammable substances.

Safety and Last Resorts

Wear gloves and eye protection. For extreme cases, use a vibration tool or impact driver to break the bond without damaging the bolt. If the bolt still resists, consider cutting it with a hacksaw or drilling as a last resort, though this may require replacement afterward. Always prioritize gradual, steady force over brute strength to protect both the bolt and tools.

How to remove a stripped lug bolt?

1. Assess the Damage and Prepare the Bolt

Before attempting removal, inspect the stripped bolt to determine the extent of damage. Use a flashlight to check if the bolt head is fully stripped or if partial threading remains. Clean the area with a wire brush or sandpaper to remove rust or debris. Wear safety goggles and secure the wheel with a lug wrench or breaker bar to stabilize it during the process.

2. Apply Penetrating Lubricant

Spray a penetrating oil (e.g., PB Blaster or WD-40) directly into the stripped threads and around the bolt head. Let it soak for 10–15 minutes to loosen corrosion or grime. Tap the bolt lightly with a hammer to help the lubricant penetrate deeper. Test the bolt with a socket afterward to see if it turns freely.

3. Use an Impact Driver or Ratchet

Attach a deep socket to an impact driver or ratchet wrench. Turn the socket counterclockwise (reverse direction) to unscrew the bolt. If resistance persists, apply short, sharp bursts of force with the impact driver to break the bond between the bolt and wheel. Avoid over-tightening, as this can worsen stripping.

4. Employ a Claw Hammer or Lug Nut Extractor

If the bolt won’t budge, use a claw hammer to gently tap the edge of a socket wrench’s drive square, creating leverage to turn the bolt. For severely stripped bolts, insert a lug nut extractor (e.g., “Inch-Pound” tool) into the bolt head. Drill a small hole into the center of the bolt and thread the extractor’s screw into it, then turn clockwise to pull the bolt out.

5. Drill or Cut the Bolt (Last Resort)

As a final option, drill a hole in the center of the bolt using a metal drill bit slightly smaller than the bolt diameter. Use a breaker bar to twist the bolt out. Alternatively, cut the bolt head off with a hacksaw or angle grinder, then unscrew the remaining shaft with pliers or a vise grip. Always replace stripped bolts with new ones afterward.