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  1. #1
    Join Date
    Jun 2010
    Location
    Dartmouth, Nova Scotia, Canada
    Posts
    157

    Default Replacing Brake Control Module (BCM) - Unable to Loosen Third Bolt

    A while back, I got the "BRAKE FAILURE STOP SAFELY" message and 80% of the warning lights in the DIM lit up.

    I took it to my local mechanic (who've been servicing the car for years) and they read the codes and confirmed the BCM was bad.

    I ordered a remanufactured one from Xemodex and watched the YouTube tutorial. I bought an E-5 Torx socket, and got to work.

    Frustratingly, I could not turn the third and final bolt that holds the BCM against the ABS pump-manifold-thingie. I rounded it over, not horribly, but enough that I can't get it loose.

    Click image for larger version. 

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    Any advice before I give up and deliver the car to my mechanic?
    2003 XC70 with 345,000 km (214,370 mi)

  2. #2
    Join Date
    Nov 2011
    Location
    Dover, NH
    Posts
    196

    Default

    This will be your friend. And don't forget the penetrating oil before hand.

    https://www.lowes.com/pd/IRWIN-BOLT-...SABEgL1LfD_BwE
    2005 XC70 Ruby Red
    2007 V70R GT 477/Nordkap

  3. #3
    Join Date
    Jun 2013
    Location
    Northeast
    Posts
    518

    Default

    Looking at your pic, I would say penetrating oil if you haven't tried it yet. I've got PB blaster but there are other options as well. Also, if you've got room to use a breaker bar of some sort - I slip a metal pipe over the end of my wrench - that can deliver a lot more leverage/torque. Now if that bolt is rounded, then I think youropeen's advice would be the approach to take.
    2007 XC70, 206,000 miles
    2002 V70XC, 130,000 miles, parts car

  4. #4
    Join Date
    Feb 2010
    Location
    Virginia Beach
    Posts
    3,854

    Default

    I have reservations about the penetrating oil, there's not much bolt, and plenty of electronics to be contaminated.

    Skip the PB'laster. It's garbage. Kano Kroil is the best. Liquid Wrench is pretty good.

    It's small. Too small for the bolt extractor-type tools. If an e-Torx stripped, there's no purchase left on the thing. I would get a dremel stone and grind it off. Buy a new bolt and be done with it. Patience and precision with the dremel and you'll get it.
    Current Fleet:
    2016 Tundra Crewmax 4WD 1794
    2005 MB S600 (100K, Michelin AS3+, M1 0W40)
    2002 V70-XC (238K, Castrol Edge 0W40)
    2002 V70-T5 (195K, IPD bars, Bilsteins)
    2001 V70-T5 (76K)
    1932 Packard Sedan (straight 8, dual sidemounts, original paint and interior, Shell Rotella 15W40)

  5. #5
    Join Date
    Jun 2010
    Location
    Dartmouth, Nova Scotia, Canada
    Posts
    157

    Default

    I went at it with my oscillating cutter.

    Working half blind and in constricted space made it impossible to neatly cut off the bolt head. I had to cut into the module some distance from the bolt, and carry on until blade met bolt.

    ...and then it wouldn't cut the bolt.

    So I jumped in my wfe's car and bought a new blade (and an angle grinder, just in case).

    The oscillating cutter maybe wasn't the perfect tool, but with a sharp blade, it zipped right through.

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    Then I had to remove what was left of the bolt. It was seized, but with a bajillion 1/12 turns of my vise-grips, I was able to get it out.

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    The new module is in, secured with only two bolts, and all error messages and warning lights are gone.

    The only outstanding item is to replace the bolt I killed. Anyone know where to get one?
    Last edited by cheapo; 11-24-2017 at 09:39 AM.
    2003 XC70 with 345,000 km (214,370 mi)

  6. #6
    Join Date
    Jul 2017
    Posts
    5

    Default I think I have one from when I did mine....I'll take a look tomorrow...

    ...and let you know.

    Quote Originally Posted by cheapo View Post
    I went at it with my oscillating cutter.

    Working half blind and in constricted space made it impossible to neatly cut off the bolt head. I had to cut into the module some distance from the bolt, and carry on until blade met bolt.

    ...and then it wouldn't cut the bolt.

    So I jumped in my wfe's car and bought a new blade (and an angle grinder, just in case).

    The oscillating cutter maybe wasn't the perfect tool, but with a sharp blade, it zipped right through.

    Click image for larger version. 

Name:	IMG_4340.jpg 
Views:	25 
Size:	97.4 KB 
ID:	8407 Click image for larger version. 

Name:	IMG_4342.jpg 
Views:	21 
Size:	93.7 KB 
ID:	8408

    Then I had to remove what was left of the bolt. It was seized, but with a bajillion 1/12 turns of my vise-grips, I was able to get it out.

    Click image for larger version. 

Name:	IMG_4343.jpg 
Views:	23 
Size:	99.6 KB 
ID:	8409

    The new module is in, secured with only two bolts, and all error messages and warning lights are gone.

    The only outstanding item is to replace the bolt I killed. Anyone know where to get one?

  7. #7
    Join Date
    Jul 2017
    Posts
    5

    Default I looked and could I not find it....sorry.

    Quote Originally Posted by necowafer View Post
    ...and let you know.
    I looked and could I not find it....sorry.

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