jezza Posted July 17, 2007 Report Share Posted July 17, 2007 Am having a problem removing one of the 4 small allen key headed screws that hold the airbox to the two metal stanchions that come off the back of the rear frame. At the moment I have the airbox off and one remaining stanchion attached by the one problem screw. I can feel the brass coloured captive nut underneath that is cast into the plastic of the airbox, rotating within its housing and because of this can't remove the screw. Problem is you can't seem to get to this captive nut from inside the airbox because it is pressed into the plastic. Anyone else had this happen and if so how did you solve it? I am having a tea break and rubbing my chin and saying "mmmmmmmmmmmmm" in an effort to generate the solution before I resort to brute force and molegrips. Any bright ideas gratefully received, any humorous replies also welcome............................... Quote Link to comment Share on other sites More sharing options...
rob214 Posted July 17, 2007 Report Share Posted July 17, 2007 sorry i don't have a clue about the box as i've never been in on yet. but on my 99 gg i had a similar problem. i just yanked out the old bolt and then used a new bolt and nut. i just used some sealant on the new bolt to seal the hole and after that i could use a wrench on the outside and a socket on the inside. it's a pain i know, i hope you get it figured out rob Quote Link to comment Share on other sites More sharing options...
the addict Posted July 17, 2007 Report Share Posted July 17, 2007 I had one like that, if you can get enough room between the air box and brace cut the bolt off to release the brace. In the end I took the brass insert out and replaced it with an ordinary nut held in place with Aralidite, it causes less damage taking it out if you heat the area up with a heat gun, never had any problems with it after that. Change all the other bolts for high quality ones straightaway and make sure you use a really good fitting allen keys when you undo them. Quote Link to comment Share on other sites More sharing options...
jezza Posted July 17, 2007 Author Report Share Posted July 17, 2007 Nice one Addict, got it sorted now, for those who may experience a similar problem this is how I did it. Used a small blow torch on a low flame and carefully heated up the screw and stanchion until there was enough 'give' in the plastic of the airbox to carefully lever out the captive nut. The nut when out looks like a small dumbell, thin tube in the middle with two nuts either end. The hole left in the airbox shrunk back to be smaller than the size of the removed nut when it cooled down. I then put some araldite in the hole, warmed it up again carefully and pushed back in the captive nut.......job done. A heat gun would be better for this......... but somehow less exciting! Quote Link to comment Share on other sites More sharing options...
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