Crankshaft Pulley Bolts - 3.0L

[1981DMC]

Hoping another set of eyes and experience of this pain will help me figure out a solution...

I have my 2003 A4 3.0L torn down to replace a leaking water pump. The timing belt and water pump were both replaced in 2014 by the PO. I called a local shop and they essentially wanted the value of the car to do the job so I chose the DIY path with specialty tools and youtube videos. The issue I'm having now is 4 stripped and stuck crankshaft pulley bolts. I do have the cams and crank locked with the special tools. I've tried heat, vice grips, even notching with a dremel tool to try and get a flathead to bite. Any other thoughts here short of just grinding them down one at a time? Constructive comments and suggestions are appreciated!

[Turbo510]

I think that step one would be to select a Torx bit slightly oversize to those stripped hex sockets, and tap/hammer it in (within reason- not super hard). The impact alone will tend to loosen them, and those screws are not supposed to be super-tight anyway. I believe that there are also tools made specifically to bit into stripped sockets. If that doesn't work, the next step will be to drill the socket heads off, using a drill the size of the holes in that pulley.

[Cybersombosis]

I’d try an easy out that fits over top of the bolt. If the wall of the easy out is too thick, if you have the ability to, take the crank bolt off and it looks like there should be enough room to get the easy out socket on the head. The other option is what Turbo510 suggested which is to drill them out but if you have the crank locked down, a breaker bar and pipe should pop that crank bolt off with some effort.

[Larhal]

Snap on, Blue Point sell a set of Torex Extractors. Just purchased a set yesterday.Quite the agressive thing.

[shurur9]

Get a set of bolt extractors.
Always a good thing to have.

The crank bolt just needs a proper 12 point socket, breaker bar and pipe handle extension.

You can get new pulley bolts at ace or Amazon.
They can be Allen heads

[Mike Tries]

Is the crank pulley bolt a one-time-use bolt?

[shurur9]

Is the crank pulley bolt a one-time-use bolt?

Technically yes.

[seanf86]

Drill them until the head pops off, there will be maybe one thread exposed you can spin out with your fingers/pliers to get it moving, I've done this on 1.8t/3.0 and 2.7t.

You can also use some extractors. I have a snap on set you pound it in and they twist farther in as you remove, with stripped hex bolts there is generally one extractor you just pound in and spin out and there is no drilling required.

[willemml]

Extractors like Larhal, shurur9, and seanf86 said are great, good to have some on hand. I used a cheap mastercraft set from Canadian Tire last time I need some.