Stripped Pinion Lock Bolt
 

I am trying to remove a G80 Differential at a local U Pull it junkyard. I got to the point where the next step was to remove the pinion lock shaft. However, the lock bolt head is stripped. (Not by me) There is not much room to work. I purchased a 1/4 drive bolt extractor set from Harbor Freight. My plan is to grind the hex all the way to the body of the 1/4 socket and cut off the excess and I am hoping that the bit will bite hard on the lock bolt and I can use a box wrench to provide the torque and leverage. If this does not work I am out of ideas. Is it possible to use a punch and a BFH to shear the lock bolt from the pinion shaft?

I test fitted the bolt extractor on a lock bolt that I have on a carrier and it fits well. I am open to any and all ideas. I plan on giving it one last shot before throwing in the towel. I know one thing no one can come behind me and pull the diff without the same difficulty.

This is on a 2000 Olds Bravada.

The head of the lock bolt has a rounded shoulder under the hex head upper portion. That shoulder can be grabbed with smallish pair of vice grips. It sounds brutal but I set the vice grips so tight that I use a pair of channel locks on the vice grip handles to lock it down. Watch your fingers!

I was able to modify a bolt extractor that is meant to used with a drill driver. I got the pinion bolt out without any trouble and was able to extract the G80 diff. I plan on using the diff. in my GMC Jimmy Diamond Edition with all wheel drive.

See attached pics of my extractor bit and of the G80

Nice work. I'm glad you got it out, and hopefully putting it in your Jimmy will go a lot smoother.