Well, the last time it went in for service apparently the tech stripped the #2 screw and now I can't get the primary off. Of course, I drained the oil first. How do I get it off there with no damage to the cover? Small screw to drill out and margin for error is fairly thin, at least with my mechanical knowledge. Any help would be appreciated!

 

Hate when that happens!!! Had to drill out both of mine, crap screw should not have too much trouble

 

There is another thread with lots of suggestions, short of going back to the dealer and kicking the sh$t outta the service tech.

Drill the head off the screw, remove the cover and twist out the stud with vise grips, or slot the head with a chisel, and use a hammer driver to remove it.

I speak from experience, stripped one myself and took about an hour to get it out.

 

Take a new drill bit that is slightly larger than the threaded part. Use a variable speed drill. Put a drop of oil on the head of the screw and start drilling.

Apply light pressure and be ready to back off when you see the head disappear.

Good Luck.

 

I have one of those Craftsman screw/bolt remover bit sets. Works great. Just need to take it real slow, apply a lot of pressure to allow the blades to dig it. The torque on the primary is not very much, it shouldn't be hard to get it out. I think the bit set cost around 20/30 bucks, and I have used it on lots of things.

I have also had luck jamming a larger size torx into the hole - for that matter, a larger torx works well to removed a stripped allen

 

the Craftsman tool seems to work well...

When I had the same thing happen, I took the Dremel, and did a 'grind' along the top of the bolt...Made it so I could use a 'flathead' screwdriver. Worked well...took about 3 minutes.

 

And when you get em out,replace em with chrome allen heads and never worry again...look all sparkly and nicer.

 

yes, yes...

sparkly and nicer is a must.

 

yep,reliable too.

 

Thanks gang for the help. Had to drill it out. Took about an hour the other night.

I purchased allen head screws to replace the torx.

Next question: What's up with the "O" ring replacement? No more rings, now it's a piece of tar paper cut to fit the primary cover?