Dealing with rusted screws is a common frustration for anyone working on vehicles, especially when undertaking repairs on older models. Rust can seize screws in place, making removal difficult and potentially leading to stripped heads or broken screws. Knowing how to effectively take out rusted screws without causing further damage is crucial for efficient and successful auto repair. This guide will walk you through proven methods for removing even the most stubborn rusted screws, ensuring you can tackle these challenges with confidence.
Method 1: Penetrating Oil and Screwdriver Technique
One of the most effective initial approaches to remove rusted screws involves using penetrating oil in conjunction with a screwdriver. Penetrating oil, a low-viscosity lubricant, is specifically designed to seep into tight spaces and break down rust. Its petroleum-based composition works to dissolve the bond between the rust on the screw and the surrounding metal, facilitating easier removal. For optimal results, apply penetrating oil liberally to the rusted screw and allow it to soak for several minutes, or even hours for heavily rusted screws. Tapping the screw head gently after applying the oil can further encourage penetration. When using a screwdriver, ensure it fits the screw head snugly to prevent stripping. For screw heads that are already partially stripped, applying a friction-enhancing material like a rubber band or specialized screw-grab drops can provide the extra grip needed to turn the screw.
Best for: Rusted screws in metal components, situations where the screw head is not significantly stripped or broken, and as a first-line treatment for moderately rusted screws.
Method 2: Leveraging Locking Pliers or Extractor Pliers
When a rusted screw resists removal with a screwdriver even after penetrating oil treatment, pliers offer a stronger grip and increased leverage. Standard pliers or locking pliers can be employed to grasp the head of the screw and manually turn it out. This method is particularly useful when dealing with rusted screws in wooden parts of a vehicle or when the screw head has become too damaged for a screwdriver to engage effectively. For screws with completely broken heads, pliers can still be used to grip the exposed shank of the screw and rotate it for removal.
For enhanced screw extraction, consider using specialized extractor pliers. These pliers are designed with unique grooves that run both horizontally and vertically on the jaws. This cross-groove pattern provides exceptional gripping power, allowing you to securely hold and turn various screw head types and even damaged screws. The vertical grooves are particularly advantageous as they allow for gripping the screw head in an upright position, providing better control and leverage compared to traditional pliers held sideways.
Best for: Rusted screws embedded in wood or plastic, screws with stripped or broken heads that prevent screwdriver use, and situations requiring a stronger grip than a screwdriver can provide.
Method 3: Utilizing Lefthand Drill Bits or a Screw Removal Kit
For larger diameter rusted screws or those with severely stripped heads, more aggressive methods like lefthand drill bits or screw removal kits might be necessary. Lefthand drill bits are designed to rotate counter-clockwise, the opposite direction of standard drill bits. When used on a rusted screw, the lefthand rotation often catches and begins to unscrew the fastener as it drills into the screw head. This dual action of drilling and unscrewing makes lefthand bits a time-saving option.
Screw removal kits typically involve a two-step process. First, a pilot hole is drilled into the center of the rusted screw using a specialized drill bit. Then, a screw extractor tool, which has reverse threads, is inserted into the pilot hole. As you turn the extractor counter-clockwise, it bites into the screw and begins to unscrew it. When dealing with rusted screws in metal using either lefthand bits or a screw removal kit, applying penetrating oil beforehand is still recommended to further reduce friction and aid in the removal process.
Best for: Larger diameter screws that are heavily rusted, screws with extremely stripped heads where other methods have failed, and embedded rusted screws that require drilling for removal.
Safety Precautions
Safety should always be paramount when working on vehicles, especially when dealing with rusted components and potentially hazardous chemicals. Always wear safety glasses to protect your eyes from flying debris, rust particles, and potential splashes of penetrating oil. It is important to remember that penetrating oils, and especially homemade mixtures often containing acetone and automatic transmission fluid, are toxic. Handle these substances with care, work in a well-ventilated area, and wear appropriate gloves to avoid skin contact and inhalation of fumes. Proper safety measures will ensure a safe and effective rusted screw removal process.
