Miguel;
I have been through a lot of what you're going through lately. I solved the
problem by doing similar: I went to fastenall and asked for the best
hex-headed replacement bolts they could sell me and nord-lock two-piece lock
washers (you should look into these if you don't know about them).

I was very, very lucky in that my wallowed out bolts (at least the worst of
them) were on the transmission side where I could get a pair of vise grips
on them to ease them out.

I never had to do it, but my strategy for any that might have been stuck in
the outer housing was to go to sears and buy an appropriate sized bolt
remover that has the reverse-threaded spiral ribs that fit over a bolt head
and grab it as pressure and torque are put on it.

If that failed, I would have driven the car to a welding shop where they
could weld on a steel rod long enough to get a pipe wrench on, a trick I had
to resort to once upon a project.

Jim

On Thu, Mar 27, 2008 at 8:36 AM, Miguel Pacheco <mundopacheco@gmail.com>
wrote:

> Installing Front Left Axle Assembly on 90 Syncro :
> I have a box full of the Triple Square style bolts ready to replace the
> infamous allen head ones. Attempt at first Allen=stripped. Attempt #2
> Allen=stripped! But, that's Ok because it's the end of my '2hr after work
> window' and it's time for my ROTR (that's rum on the rocks!)
> Now it is a new day and I have 10hrs before the end of my workday, and the
> beginning of another 2hr work window, to search for interesting tips to
> help
> me out of this bind. Anyone know of any tricks to remove these stripped
> allen head bolts?
> I've done this job quite a few times and never had this problem, not once.
> As always, I soak these with penetrant, clean the recess meticulously, tap
> the allen socket into place and gently (never using an air ratched)tug
> until
> the bolt releases. Oddly enough, this was to be my first replacement of
> these with the Triple Square style.........
> Thanks!
> Miguel..stripping for attention
>