How to get rusted-up bolts/screws free with restricted access - help!

ripofflondon

Hi all

Am trying to fit a replacement bottom-entry flush valve in my toilet cistern - that's not the issue.

What IS the issue is that it's a close-coupled one (didn't even know what that meant before today!) and I have to get the cistern separated from the toilet bowl so i can unscrew the old valve assembly and replace it before reattaching the cistern to the bowl. 

Here's the problem: the cistern is attached to the bowl by the 2 bolts/screws you can see circled red in the photo BUT they are rusted solid plus the access either into the cistern from above, or from below/behind the bowl, as you can see from the pics, is extremely limited.  I have pulled away the rubber washers that were there originally, plus chewed away at the screw heads as best I can with pliers / claw hammer etc but the lack of access, plus the fear of cracking the ceramic cistern/bowl, means I'm currently stuffed.  What to do?

HELP!  

Mark

molerat

Carefully drill the tops out.

pieme

Can you get a drill onto the screw heads? Drilling might loosen them, and looks like they are pretty well chewed up anyway, so nothing to lose. Or if not, can you get a junior hacksaw in to saw the bottom bolts off flush with the nuts, and drill from below?
As you say, the normal brute force methods are ruled out because of the ceramic.
Or maybe a Dremel type hobby cutting disc might get to those screw heads?

Eldi_Dos

Get a junior hacksaw and cut a slot in the bottom of the bolts, suitable to take a flat blade screwdriver.
Then get spanner onto nut and screwdriver into slot and turn screwdriver to break rusted seal between bolt threads and nut, a bit of care needed to turn the right way.

OutdoorQueen

As above, but soak in a WD40 type spray as well.  

mexican_dave

If you can identify the flush valve you are removing, then just buy the same replacement, then there is no need for all this, the new flush will connect to the part fixed to the bottom of your cistern. Similarly if you know the make and model of the WC, if is a good brand you will be able to order a replacement cistern - should it break on you.
And finally, remember a bog standard white close coupled WC (no pun intended) costs about £120 (more or less), is it really worth all this hard work to remove the bolts? As Clint Eastwood once said, "A man has got to know his limitations".

Micron

Not an easy job but I would persevere with trying to drill off the bolt heads.

If all else fails and as a total last resort you could try a nut splitter, from the photo it looks as if you might have just enough room to be able to use one.

Honesly, it's not somthing I would ever want to do myself,  I would guess that the amount of torque you would have to apply on the splitter to split the nut would result in breaking the toilet bowl, holding the splitter with a pair of mole grips might be enough to negate the twisting motion.

Good Luck.

Toolstation Nut Splitter

twopenny

I've been sucessful with loosening corroded screws by repeated spray with wd40, washing up liquid, oil.... basically lubricants over a day or two.

When the screw heads are mangled, cut a piece of wide rubber band (post men often drop them) place it on the screw head, put the screw driver in the center and that gives the grip to remove them.
Works like a charm   

chrisw

Can you get a deep socket over the nut?

onejontwo

Try using a penetrating oil solely designed for penetrating rusted on nuts and bolts.( not wd40 as that' more of a lubricant/water displacer)
and leave for 24 hours. 

GDB2222

Possibly you can cut the nuts off with a multi tool.