If the bolt is already stripped, I have had some success hammering in either a Torx or standard hex that is slightly larger than the original metric size.  Obviously, after removal you would want to replace it with a new fastener.

Scott Walker
  ----- Original Message ----- 
  From: Jason Willenbrock 
  To: vanagon@GERRY.VANAGON.COM 
  Sent: Sunday, September 07, 2003 10:52 PM
  Subject: hex bolts

  why did vw have to use so many hex bolts?
  every vanagon i have owned, i have stripped the hex bolts trying to remove them, wether it be on coolant stuff or on cv stuff.  most recent, the hex bolt on the left engine side, metal coolant pipe from thermostat housing to h20 pump. the under hex bolt at pump which is hard to reach.  i can  not get my 6 mm hex key to fit.  it is border line stripped.  if someone has a good ideas, it can still be removed.  i tried hammering it into place to no avail, corrosion is strong.  i need to remove this to replace h2o pump.  will keep working at it tomorrow, i just wanted to vent my frustrations with hex bolts?
  am i alone here, or does everyone have these problems
  jason
  90gl
  87 syncro westy project

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