I read all the threads I could before I started, and did what everyone suggested, but after 3 hrs the blocker plate is not installed an I think I am SOL. After fighting the top nut for an hour, I finally broke it loose with a 1/2" wratchet.;) After 30 min on the bottom nut with no luck, I cut an 8 in piece of pipe for a cheater bar. I was very happy when the wratched started to turn with the cheater bar,:D but the happiness turned to disgust when I realized I just jacked up the nut!:mad: I must have been at a funky angle cuz now the nut is completely rounded and I can't get a grip on it at all.

Any thoughts or am I really SOL.

I read all the threads I could before I started, and did what everyone suggested, but after 3 hrs the blocker plate is not installed an I think I am SOL. After fighting the top nut for an hour, I finally broke it loose with a 1/2" wratchet.;) After 30 min on the bottom nut with no luck, I cut an 8 in piece of pipe for a cheater bar. I was very happy when the wratched started to turn with the cheater bar,:D but the happiness turned to disgust when I realized I just jacked up the nut!:mad: I must have been at a funky angle cuz now the nut is completely rounded and I can't get a grip on it at all.

Any thoughts or am I really SOL.
probly SOL with that nut rounded off. i used penitration oil and cam eoff in a jiffy. sorry to hear about your frustration.:o:

I brought an Snap-on Nut removal set (i think irwin do a similar set) few months ago. You can use a 3/8" breaker bar/ratchet or a 17mm/19mm spanner on the outside to turn the tool.

They have a reverse twist inside the socket which grab the nut (or stud) and undo.. Not found anything it won't grab yet. After nut if off, change it out.

It sounds like its time for the dremil tool just don't destroy the stud.

Did you soak them before starting? Might try the nut remover kit that was mentioned, heat maybe, or a nut splitter if there is room...Never SOL, keep in mind it is a tiny nut and you are a big guy!:D I work on C-5 aircraft that are almost 40 years old, have bolts with nuts 10 times the size you are working on and they are a blast to get out when stuck! Good luck...:grd:

I used a long handle snap on swivel ratchet.

I never new nut splitters or nut removers existed. Just ordered a nut splitter since they are a bit cheaper than the removers. Will try again next weekend.

Thanks everyone for your advice!

Definitely a PITA.....I twisted off BOTH studs on mine! Had to drill them both out and redrilled for 3/8" bolts. Lucky thing the Kodiak has a dog house that provides easy access to them suckers!

I never new nut splitters or nut removers existed. Just ordered a nut splitter since they are a bit cheaper than the removers. Will try again next weekend.

Thanks everyone for your advice!

Sorry for your bad luck,

Not sure you are going to be able to get a splitter in there. Please let us know if it does work for you, that will be another good piece of info to have.

I got a set of the previously mentioned "nut buster" sockets for Christmas a couple of years ago. Don't think they were all that expensive (Craftsman), and they will fit in this application.

Fortunately, I never had to find out if they will both fit AND work in this case...

Bummer. Good luck to you. Don't give up, you will get it. When you do, treat yourself to a cold beverage.

I installed my EGR plate today. Those nuts were tough to get off. I was not strong enough to push the 1/4" ratchet enough to pop them loose. The 3/8" racthet wouldn't fit in there. I ended up fitting the end of a small chain over the end of my 1/4" ratchet handle. I put a zip tie around the handle and under the chain to keep it from sliding down the handle. Then I pulled the chain from the driver's side of the truck. I was very careful to make sure the socket fit the nut well, was on straight, and my pull was in line with the plane of the nut. Worked like a charm, both nuts popped right off, I could not believe it worked. I am posting this in hopes that someone else might benefit from it down the road. I didn't use penetrating oil, but would do that if I had to do this over again.

I had some trouble getting the plate all the way down also. I had to try to three times before I got it all the way down. Nothing but the handle should stick up past the flange. Be careful not to booger up the existing gasket.

I read all the threads I could before I started, and did what everyone suggested, but after 3 hrs the blocker plate is not installed an I think I am SOL. After fighting the top nut for an hour, I finally broke it loose with a 1/2" wratchet.;) After 30 min on the bottom nut with no luck, I cut an 8 in piece of pipe for a cheater bar. I was very happy when the wratched started to turn with the cheater bar,:D but the happiness turned to disgust when I realized I just jacked up the nut!:mad: I must have been at a funky angle cuz now the nut is completely rounded and I can't get a grip on it at all.

Any thoughts or am I really SOL.

I just installed mine today. I found that using a set of racheting gear wrenches was the best method. Those hex fastners are TIGHT. I had to give it everything I had to bust em loose.

In regards to your situation...take it to a welding\muffler shop. All that needs to be done, is to weld some nuts to the stripped ones, let them cool, then break em loose with a wrench. No damage to the studs need be done. EASY.

A small torch heating up a nut can do wonders for stubborn ones,anyone tried that on the blocker plate install?Breaking off a stud would not be good at all!

I feel your pain, went through the same thing and after 2 hrs finally got them off. Problem is I couldn't get the plate in right and was so pissed after the whole ordeal, I threw the plate and haven't got it out from under my bench yet.

I just installed mine today. I found that using a set of racheting gear wrenches was the best method. Those hex fastners are TIGHT. I had to give it everything I had to bust em loose.

In regards to your situation...take it to a welding\muffler shop. All that needs to be done, is to weld some nuts to the stripped ones, let them cool, then break em loose with a wrench. No damage to the studs need be done. EASY.


Great idea! Hum......on the other hand I have been considering buying a welder!! Now I just need to convince my wife I need a $400 tool to install a $14 doller part!! Stranger things have happened!

I feel your pain, went through the same thing and after 2 hrs finally got them off. Problem is I couldn't get the plate in right and was so pissed after the whole ordeal, I threw the plate and haven't got it out from under my bench yet.

I'm going to give it one more shot this weekend. If I finally do get that nut off and can't get that plate in, it will be living under my bench as well!! Hope this is all worth it!

Great idea! Hum......on the other hand I have been considering buying a welder!! Now I just need to convince my wife I need a $400 tool to install a $14 doller part!! Stranger things have happened!
Remember it is easier to say " I'm sorry" than it is to beg.

Remember it is easier to say " I'm sorry" than it is to beg.

:lol: true true!

Well I got the nut splitter today and it fits, but was way too scary messing with that thing blind!:o: I cranked on it a few times and figured if I kept going I would really be hosed when I screwed up the stud. So it's off to Sears tomorrow for the nut removal set.

Use heat on stubborn nuts and bolts. Heat them to a very slight glow and they will come off very easy.

Nearly 10 hrs of my life has been wasted over this plate so now I'm done!! :mad: I spent 2 hrs last night trying to get that nut remover to get a good bite into that nut. Thought I had it a few times but no luck. I spent another 1.5 hrs looking for the nut remover that fell to no mans land!! I even had towels against the fire wall but it's gone. I looked for another hr this morning, nothing. $14 for the plate $15 for the nut splitters, $30 for the nut removers (now missing one) and the plate is still on the shelf. Guess I got some tools out of it.

Now I'm just going to load up the boyz and head for the hills and take some frustration out on the accelerator (responsibly however, with the Boyz in tow).:)

Nearly 10 hrs of my life has been wasted over this plate so now I'm done!! :mad: I spent 2 hrs last night trying to get that nut remover to get a good bite into that nut. Thought I had it a few times but no luck. I spent another 1.5 hrs looking for the nut remover that fell to no mans land!! I even had towels against the fire wall but it's gone. I looked for another hr this morning, nothing. $14 for the plate $15 for the nut splitters, $30 for the nut removers (now missing one) and the plate is still on the shelf. Guess I got some tools out of it.

Now I'm just going to load up the boyz and head for the hills and take some frustration out on the accelerator (responsibly however, with the Boyz in tow).:)

Sorry to hear that man, it is a painful install. If you ever feel like getting back after it- warm the motor up first. Park it and let it cool enough that you can stand it, then try and break those nuts loose. Heat makes a big difference.

I have come up with the ideal procedure for breaking loose those problem EGR bolts. By using a MAPP gas hand held torch on the flange side, which has the actual threads - the bolts break free with almost no effort.. No need to run/heat the engine - just fire up the torch & you are good to go!

Try warming the nuts up, just not red hot, and trickle penetrating oil in the bolts. (take the flame away first) You will see the oil actually suck back in the treads.This will tend to smoke a little and where its located make sure u have a fire extinguisher in case of flame. I have tackled a lot of rusty farm equipment with this method.

I feel your pain. This was a PITA install for sure! It took me 2 attempts to finally get mine in. The first time I did not have a deep enough 12mm socket. I bought some PB Blaster, and a new set of sockets for my second attempt. I managed to get the bolts soaked, and let the PB set in, then did it again.

The nuts broke free eventually, but prying apart the bottom end of the EGR was a mofo! I managed to get the plate in far enough, and eventually tapped it in the rest of the way with a piece of wood, and a small hammer.

Don't give up, you will eventually overcome the obstacle!

One thing that helps that no one has mentioned; Whenever possible, use a 6 point socket or wrench. These have a larger bearing surface and are not as prone to rounding off the corners..........:)

I was able 2 break my nuts loose pretty easy, and im not that strong of a guy. I just got lucky.