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Thread: How to remove M6 rounded/seized screws from MK5 door?

  1. #1
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    How to remove M6 rounded/seized screws from MK5 door?

    I recently acquired another MK5 GTI (can't help myself) and was set to replace the door lock actuator, so removed the door skin and then get to removing the M6 screws holding the actuator in place, but managed to round off the screw so that I can no longer remove the screws anymore.

    I suspect that the actuator has already been replaced once before as it was hard to even get a grip using my wrench with the M6 bit onto the screw.

    How can I go about removing these screws?

    How to remove M6 rounded/seized screws from MK5 door?-img_3538-jpg

  2. #2
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    Cut a slot with a Dremel or file and use a large screwdriver.
    Or if you're a Neatherdal like me use a chisel and hammer at an angle to lefty loosey it to get it started then remove by hand.
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  4. #4
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    You can try a stud extractor.

    Drill into the Torx socket and start the stud extractor into it.

    Another way would be with a Torx bit and an impact wrench.

    In case it is rusted, give it a good WD40 soaking.
    --


  5. #5
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    Possibly stripped before by someone using M6 allen key instead of T30 torx bit. But how did both get stripped out?
    At least they are easy to drill out and a small easy out will shift it.
    Last edited by carpy; 25-09-2023 at 07:37 AM.

  6. #6
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    Slots, chisels and impact drivers are your friends. At least these are visible! Inevitably it's the ones upside down and under some dash wiring that seem to be stripped for me


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  7. #7
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    Thread Starter

    Quote Originally Posted by carpy View Post
    Possibly stripped before by someone using M6 allen key instead of T30 torx bit. But how did both get stripped out?
    At least they are easy to drill out and a small easy out will shift it.
    Can I use a T30 torx for these?! Every tutorial I've read/watched mentions M6, but I found it hard to get a good grip with my M6 bit.

    Both are gone because I made them worse trying a bit too hard.

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