I was in the process of greasing my A/C idler pulley when i stripped out the torx bit drive on the bolt. I was wondering if anyone would know what method i could use to get bolt out.
Thanks

 

Buy another torx bit?

 

I stripped the actual head on the bolt, My bit is fine.

 

Have you tried a slightly larger sized Torx bit? Otherwise, you might have to try using vice-grips.

 

Try beating in a regular screwdriver with a hammer if you have no other options.

 

drill and easy out

 

Its in such a tight place that theres no room for a drill, and there really isnt anything to grip with a vice grip. I was thinking of using a dremel and trying to cut the head off of the bolt.

 

Yeah, that is a tight spot, especially since it's kind of recessed inside the retaining washer. Can you get whole tensioner assembly out so you can work on it on a bench? Then you can weld a bolt on it or drill/easy out.

Mine was pretty easy to get out. Is it possible there is dirt in the recess so torx bit doesn't completely engage? If so, dig the dirt out and see if bit can still grab.

 

Yep, pull the tensioner and fix it. Then if you don't have the right tools to do it you can take it to a shop that does.

 

I was able to fix it. I used a 90 degree die grinder and ground the head right off the bolt, slid the pulley off, and used a vice to get the bolt out.
It actually worked out pretty nice