Rep Power: 0

Hey guys I have an issue trying to remove the Air Filter Cover to change the air cleaner element. The bolts are rusted to hell. I managed to get 3 of the bolts off but the other ones are locked due to severe rusting. I tried grips, clamps and even drilled a hole down the center and when using a bolt remover bit it snapped inside.

I have come across articles where gents' have surrounded the bolt with silly puddy and created a pool like effect by inserting WD40 and letting it sit. This will be my next step. But for now my bolt is deformed from applying grips to it.
I am getting impatient.

Should I continue to drill through the snapped bit?
Break the plastic and get a new housing?
Any recommendations?

 
Rep Power: 156

soaking it with WD40 or something like Liquid Wrench would probably be est. If not then you can continue to drill it out. I'd get a step bit (maybe known as unibit) and just drill it down enough so the head pops off. Then try to take the bolts out.

http://www.lowes.com/pd_60140-281-10...ductId=1094161

 
Rep Power: 518

Buy a new filter housing, both upper and lower halves.

 
Rep Power: 308

Used to keep the ones on my 05 lubed to prevent this from occurring..... bad design with the exposed threads.

 
Rep Power: 146

Drilling out the bolts will be very difficult, espicially if they are really stuck.

The bolt threads into the 'nut' on the bottom of the housing, but the 'nut' is just a serated piece of metal formed into the plastic. With enough drilling (and heat, from drilling) the 'nut' will just start to spin in the housing, causing it to be permanently stuck! Happenend to a friend....

You could probably find this part from a salvage yard for like $40... Or the dealer

 
Rep Power: 0

Just following up. I managed to get the cover off and replace the air filter. I ended up cutting the head off the rusted bolt with a dremel and the cover was able to lift. I did not notice before that the two bolts in the back were not connected because the housing snapped. I replaced all the bolts that I could. I left the stem from the cut bolt in the thread. I have 3 bolts around the cover and the one in the center still in place. See attached. Thanks guys.

 
Rep Power: 146

My only worry would be that since all the bolts are not in place, the filter may not seal as it was intended to, causing air to be drawn in from around the filter, effectively bypassing it. Probably still a good idea to get a new filter housing. Its really easy to replace too...

 
Rep Power: 518

LOL

 
Rep Power: 210

take the redneck approach,

get a K+N air filter,

seal around the entire filter edge with silicone,

slam the top on and never touch it again,

 
Rep Power: 156

can you zip tie the lid down? I don't remember what it looks like