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Discussion Starter #1
Hello fellow Zuki-heads
I have a 1986 Samurai tintop with the 1.3l motor and 5spd tranny about 67k mileage wise.
Anyhow, I just moved to Salt lake city and I towed my zuki here, now it won't go into first gear because I blew a synchro in the tranny, which I knew I would have to rebuild eventually and now is the time I'd reckon.

Here's my dilemma, one of the first steps in removing the transmission is to loosen the starter bolts and slide the starter forward, but the lower bolt is giving me hell which I think is mostly due to the battery negative ground wire pushing my socket off the bolt and after several different (unsucessful) angles I have totally stripped the head of the bolt off and even using those special stripped out sockets I can't seem to get it off.

Has anyone else ever had this issue in getting it off? it's in a really weird spot so most stuff would be hard to fit in there so I'm not even sure what to try next after using the stripped removal sockets to no avail. I tried pb blaster and tapping with a hammer first.

any help would be GREATLY appreciated it would be nice to back on the road before the snow starts falling here!

Thanks a million,
Jim
 

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I`d have the engine and gearbox swinging by now,Earth wire and all.No more difficult to pull the lot , and probably easier to reinstall. It Will be much easier/possible to repair the damage with the whole lot out. A drill a center punch ,set of ezy outs and a tap and dye just incase.
 

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Discussion Starter #3
Well I'm really trying not to make it to complicated I'm literally trying to do it on the side of the road at my apartment complex so I'm not sure I have the equipment to pull the whole engine and tranny anything else you could think of?
 

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Not a great place too work , but i have done a gearbox on the side of the road ,It`s more then possible and encourages fast work.
Maybe a good set of vice grips on the flogged bolt , Make sure to nip up the top bolt 1st. If the top bolt is loose it will add pressure into the bottom one making it harder to turn
 

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Discussion Starter #5
Well I'm still having a hard time with this, I tried the vice grips but they won't even fit in there to grip it, I tried heating the bolt up but it's so stripped I can get any sockets or wrenches on there to grasp it, I really don't know what else to do short of cutting the damn mount off of the transmission which I'd really rather not do (don't really have the tools for it either).

Any other Ideas?

thanks again
Jim
 

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starter bolt

Some one used to make a socket that is filled with
round hard steel small rods. When applied to a
rounded bolt the rods lock on and help twist the
bolt out of its location. Can't find it in my tool
box now so cannot tell where or who it came
from but a quality auto tool store should be able
to point you in the right direction.
It was a 3/8 drive socket, used on a swivel head
ratchet that seemed to work well for those exhaust
and other rounded bolt heads. Worked on rounded
nuts too.
 

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I believe Irwin makes those rod sockets, I have a set to but my tool box is under lock and key elsewhere until I find a serious buyer.

I would refer back to the sockets with the rifled looking innards for stripped bolts, its a tricky position anyway but I have had excellent luck with those sockets.

I know this is really reaching but if it were me I would consider heading on down to the local pawn shop and buying a crappy throw away 3/8 extension for a buck or two and weld it directly to the head of the bolt and try it that way. That is, if you could get a wirefeed up in there far enough to touch at least two opposing clock positions on the bolt head. I have gotten badly stuck and stripped bolts this way but not in that position. Again I know it's reaching but alternatively rent a cherry picker and yank the engine/trans right there in a feverish session of "lets get this done on the quick before anyone says anything".

I hope you find a way to make it work.

I know your mileage is low-ish but because of the years I cant help but think that if the engine were out it would be a super convenient time to go ahead and replace the timing belt/idler/WP.
 

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Discussion Starter #8
Strangely enough I have changed the timing belt and tensioner, front seal and all those goodies in front there. Is there anyway to remove the transmission with the starter still stuck to it? maybe just disconnect from the block or whatever else it's attached to? Those rifle looking sockets are the ones I have and the 12mm size is supposed to fit on there but it's too stripped to get a hold on it and the 11mm won't fit on there because it's too small so those are out I'd say. It's starting to get cold here so I gotta get this done sooner rather than later.

Thanks again,
Jim
 

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Discussion Starter #9
As an Update I did get the bolt off by heating it up and pounding a 11mm combo wrench on it which gave me enough grip to pull it off, the rest of the rebuild went without a hitch and she's back on the road! I also just picked up a SWEET JS tintop with a restored interior for $900 so I'll probably post a thread of my frankenstein project that I'm gonnna do with the two of them
 
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