Breakoff screw blues

[Rammin On]

No need to punch the screw . . just drive the torx bit in ... I'm down here in Meraux ... visiting my son in Lexington Place ... I can help you if you wish. E-mail headed your way

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'95 2500 Stretch 4X4, Auto, 3. 54, 265/75/16, white. TST #5 250/635 plate, 215/230 injectors, Pschotty Air, Cummins chrome, BD Valve Body, Pro-torque LS convertor, BD pressure-loc, mystery switch, JRE 4" turbo to tailpipe w/ monster tip, BD exhaust brake, ISSPRO boost and pyro, Grover air horns, Pioneer CD system, Galaxy 99 CB w/ 400 linear, nerf bars, Rancho 9000's, 8K tag-a-long RV ... Life is Good!

 

[gitchesum]

The breakoff screw on mine was a little stubborn. I ruined two torx bit trying to get it off. Rounded off the edges hammering them in. I will comfess they were a cheap tool bought just for this occasion. I ended up using a long chisel and going at on the edge of the screw. Had to get at it from the front of the engine. That was the last resort. Worked great and everything is back and running.

On my 94 I had no trouble with the Torx bit. Worked great.

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Curtis Harris

"JAWS"(The Great White)
Updated 11/19/00
1997 Club Cab Dualie
correctly valved 5 speed. White, Brown Manf. brushguard and rear bumper,Sprayed in liner, Stock plate and AFC properly adjusted. Straight pipe. That's all for now. More to come.

 

[Iceman1]

I used the torq bit method. Just a word of warning though when doing that - make sure when ya orginally punch the center hole that it is centered to the best of your ability. Other that that it is easy. Also be sure to slide the AFC all the way forward. And ya might adjust the AFC starwheel for more power at lower RPM.

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1997 3500 SLT, Ext cab, 5spd, TST #11, GV Aux Trans, BD exhaust, Kelderman Air Ride, 60 Gallon fuel tank, Clifford Security, Reese 20k 4way 5th wheel hitch, Boost/EGT gauges, K&N air filter, Rancho RS9000 shocks, Brush Guard, DZee full length running boards.

 

[HEMI®Dart]

The #20 Torx bit works great to remove the breakoff screws.

Its best to get a long 1/8" drill bit and drill the break off screw head about an 1/8" deep. Then tap the torx bit into the hole.

I fact my #20 torx bit still has a breakoff screw stuck on the end of it! The torx bit really bites hard with the 1/8" pilot hole.

[This message has been edited by HEMI®Dart (edited 12-24-2000). ]

 

[Koa Man]

Don't replace the breakoff screw with another one. Use a hex or allen head. You will probably want to play with plate positions, AFC springs etc. You are already your own warranty station so not having the breakoff screw does not matter.

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1996 3500 Clubcab SLT, auto, 4. 10 limited-slip, TST #5, 370s, AFC spring kit, Physcotty, Dunrite converter, Trans-Go, DiPricol EGT, boost & trans temp. gauges, 9 ft. aluminum flatbed and tool boxes with Venco dump. Custom front bumper, Hadley air horn, PowerVision mirrors.

 

[Swamp Donkey]

I used a busted off chunk of hacksaw blade to cut a slot in mine. This is after I busted off a torx. The other ways sound much neater and easier. Especially pre drilling the hole. I had to get it off, and the hacksaw blade worked.

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John McEachern
Fort St John B. C. Canada
1998 12v, 4X4, QC, auto w/tc switch, air, tilt, cruise, 3. 55 gears, TST #6, Isspro boost/pyro/transmission gauges, BD VB&TC, CC industries headache rack and rails, JVC KD-SX949 Cd player, forest green, Brigestone Dueler M/T's 285/75/16, Eagle 16x8 rims, K&N airfilter.

 

[danandamy]

My break off screw was stubborn too. The torx just rounded off in the hole. A little friendly persuation with the chisel did the trick! #ad


Daniel

 

[PUMPERDUDE]

There is a Santa. I believe. CAN YOU BELIEVE 13 minutes after making this post a guy from VA says hey,let me come over and help you put in that TST plate. He traveled 1036 miles to visit his son and winds up helping me put my plate in. He just hammered the # 15 torx in and out she came. THANKS KEITH. [WHO EVER HEARD OF MERAUX ANYWAY]

[This message has been edited by PUMPERDUDE (edited 12-24-2000). ]

 

[Sled Puller]

I just tapped 'er 4 times with a chisel, and backed 'er out with my fingys. Put in a hex.
Do we have different break off screws?
Gene

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1997 Cummins Dodge 4x4 Bombed & Amsoiled. Amsoil Premiere Direct Jobber, Member of: NRA Business Alliance, GLTDR, WANTED: Wrecked Dodges.
www.awdist.com

 

[dieselshadow]

I had to use a dremel tool to cut a slot in it after I broke my torx bit off in it. I replaced the screw with one from the hardware store for a nickel. My . 05 cents worth! Merry Christmas!

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J Case
'95 2500 4x4 Auto Reg Cab
BD tc, vb, Pressure lock, #5 fuel plate, 4" exhaust, and K&N RE-0880.


BOHICA!!!!

'99 KTM 300 EXC

 

[PUMPERDUDE]

OK guys. Just got my #6 TST plate from Santa. #ad
The only thing holding me back is,I want to know the best way to remove the breakoff screw. Instructions say punch it then torx # 15 or 20 hammered in. Does it work? Thanks Guys.

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1995 Club Cab 4WD 5. 9 SLT,29. 5 ALJO SUPERSLIDE

 

[Rammin On]

Timmy ...

Glad I could help! Gotta love the power! Thanks for the Satsuma's they are sweet and tasty. I forgot to get your address before I left yesterday. Send me an e-mail so I can send you the hex head screw.

Keith

 

[Macmc01]

I was going to try the torx method but do you have to remove the injector lines to get to it?
Any help would be appreciated.

Mac

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95 Ram 2500 Auto Std Cab, Cat & Muffler Fell off, 125,000 miles.
Bombed-to-be!

 

[Rammin On]

Nope ... you don't need to remove the injection lines ... just use a torx screw driver and drive it in the breakoff screw. Go between #5 and #6 lines. Enjoy!

Keith

 

[KB0OU]

Just got a #8 plate,,, just how far forward should I push it before I put the lid back on???

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96 CC 4X4 2500 SLT AUTO transmission, PrimeLoc, ISSPRO EGT Boost transmission Temp, GUTTED CAT, 150,000+ Miles still goin' strong, Lots of Ham Radio gear, NO IGNITION NOISE!!! Love my diesel!!! TST Fuel plate on the way, BOMBS AWAY!!!

 

[C Schomer]

When I did mine, I took a look at it and said, screw the Torx bits and chisels and just drilled the whole head off with a long 1/4" bit. After the cover is off the stub can be unscrewed. It can't get any easier! Craig

 

[illflem]

I used a left hand(cc wise turning) 1/8" bit,the kind you use for removing broken bolts. On both my rigs the bit caught and unscrewed the bolt. Pretty darn easy.

 

[KB0OU]

Just went to NAPA and got 4 DOR 423-220 cap screws for $1. 11. When I put my #8 plate in 4 screws with same heads etc. will hold my AFC cap on. I hate to have to change wrenches when working on a single item. Why doesn't tst send these with the kit?? Or at least 2 like the screws on the drivers side of the cover??? Now I still can't make up my mind how far forward I want that plate to go.

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96 CC 4X4 2500 SLT AUTO transmission, PrimeLoc, ISSPRO EGT Boost transmission Temp, GUTTED CAT, 150,000+ Miles still goin' strong, Lots of Ham Radio gear, NO IGNITION NOISE!!! Love my diesel!!! TST Fuel plate on the way, BOMBS AWAY!!!

 

[Forrest]

KB0OU,

All the way forward, of course. Try it centered for awhile. Then slide it all the way forward, along with the AFC housing & let us know if you think it made any difference. #ad


I got one of those #8 plates sitting in front of me. I got it by mistake. #ad


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Money Sink - 96, 5 speed, HX40-16, TST #11/280 slid 3/4 way, 300 HP Injectors, Scourge BD Governor kit.
4" CATless turn down straight out back.
ISSPRO Pillar, Delvac 1 & Amsiol, RE-0880, Mag-Hytec, 3:54, 235s on Alcoas, Rancho 9000's, Valentine One.
Clutch days are numbered, McLeod on the way.
#11 plate days are numbered, custom grind on the way.
Dutchmen 27' 5th Wheel.
GoldWing.

 

[Joseph Donnelly]

The driver's side capscrews are 25 mm long. The breakoff and slotted head screws are 18 mm long (you can use 20 mm long). There may not be enough clearance for ordinary hex head screws, but Allen heads work fine. Put some grease on the threads. Often the screws are very tight because they have corroded into place.