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

[cheapo]

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.



Any advice before I give up and deliver the car to my mechanic?

[youropeen]

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

https://www.lowes.com/pd/IRWIN-BOLT-...SABEgL1LfD_BwE

[Xfingers]

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.

[Astro14]

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.

[cheapo]

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.



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.



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?

[necowafer]

...and let you know.

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.



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.



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?

[necowafer]

...and let you know.

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