How To Remove A Rusted Screw With A Stripped Head—3 Simple Methods

When working on a 2005 Ford Focus a few months ago, the work was going smoothly until I met four rusted screws with stripped heads. The screws were stubbornly logged in the component, and they refused to budge.

Below, you will learn how to remove a rusted screw with a stripped head in three simple methods. Each method is quite effective, as you would imagine. However, it requires time and patience, as I spent up to two hours removing these rusted screws. Grab a seat and a cup of coffee while I walk you through these simple methods.

How To Remove A Rusted Screw With A Stripped Head

There are several ways you can remove rusted screws with stripped heads. But in this article, you will learn the three most effective methods, which include screwdriver and penetrating oil, locking pliers or extractor pliers, and screw removal kits or lefthand drill bits.

Method 1: Removing a rusted screw with penetrating oil and screwdriver

One of the easiest methods of how to remove rusted screws from a car is using penetrating oil and a screwdriver.

Step 1: Clean the screw areas

When using this method, the first thing you should do is to clean the screw and its surrounding with a wire brush. This will allow the penetrating oil to soak the rusted screw properly.

Step 2: Tap the screw

After cleaning the screw, tap the screw head a couple of times with a tapping hammer to loosen the rust that is holding the threads. Place a screwdriver or a bolt on the screw head before tapping it so you will have a good impact. Keep in mind, do not use a nail or any pointed object to avoid damaging the screw.

Step 3: Spray penetrating oil on the screw

If you are using a penetrating oil that has a straw, such as WD40, attach it and spray the oil on the rusted screw. Spray it properly and let the oil sit for 15 to 30 minutes.

Step 4: Tap the screw again

While waiting for the oil to soak the rusted screw, tap the screw again to make the oil circulate faster and break loose the rust holding the screw threads.

Step 5: Remove the rusted screw

Get a correctly sized screwdriver and screw out the rusted screw. If, however, the screw head is partially stripped, the screwdriver may not hold the screw head. In such a case, get a rubber and place it on the screw head before putting the screwdriver. The rubber will fill the void on the stripped area and improve the friction.

Method 2: Removing a rusted screw with locking pliers

If you are searching for how to remove a screw with no head without a drill, this is one of the best methods to consider.

Step 1: Clean the screw and its surrounding area

First thing, first. Clean the screwdriver and its surrounding areas with a wire brush. The rust could be just on the surface, and cleaning it could be all you need to get it loose.

Step 2: Remove the screws with locking pliers

Grip the stripped screw with a locking plier on the shank or head. Ensure you hold the screw from the side so the grooves on the plier will grip it properly. Gently turn the screw counter-clockwise to lose it. If it becomes hard at any point, return it and go again until it becomes free.

You can also use extractor pliers if you don’t have locking pliers. Both extractor and locking pliers are great tools for this task. However, I prefer locking pliers because it holds the screw, relieving you of that task.

Method 3: Removing a rusted screw with a drill bit

Drilling is the best solution for removing stubborn, rusted, and stripped screws. However, you should only use this method only when the other two methods above could not remove the screws.

Step 1: Clean the screw and its surrounding

Much like the other two methods above, clean the screws with a steel wool or wire brush to remove paint, rust, or corrosion from them. Ensure nothing is blocking the screw heads so the penetrating oil will do its magic when you apply it.

Step 2: Tap the rusty screw

Place a bolt or screwdriver on the screw and tap it a few times using a tapping hammer. This will help the screw feel the impact pretty good.

Step 3: Spray penetrating oil

Now, spray enough penetrating oil on the screw and let it sit for 30 minutes or more.

Step 4: Select the right size drill bit

Take a lefthand drill bit that is a diameter less than the thread size of the screw.

Step 5: Drill the rusted screw

Firstly, chuck the drill bit into an electric drill and tighten it by hand. Ensure it is properly tightened. If it’s not properly tightened, the drill will loose since you will set it to turn counterclockwise.

Coat the screw with a cutting oil. Set the drilling machine to reverse and drill the center of the screw. Keep your hands straight and maintain slight pressure while drilling. Keep drilling until the screw head is completely off.

Step 6: Remove the screw thread with extractor kit

Now that the screw head is out of the way apply a penetrating oil on the screw thread and let it sit for a minute or two. Grip the screw with an extractor kit or a locking pliers. Gently turn the screw counter-clockwise until it comes off.

Safety Precautions For Removing a Rusted Screw With Stripped Head

We cannot discuss how to unscrew a rusted, stripped screw without talking about the safety considerations. Here are some things you need to consider:

Final words

If you have been reading to this point, you have learned how to remove rusted screws from metals, plastic, and wooden surfaces.

This article has explained how to remove stripped screws with penetrating oil and screwdriver, locking pliers, and drill bit. Choose whichever method you think will work best for you.

Each of these methods has its advantages and disadvantages. So it’s best to look at these methods carefully before choosing to get the right method for your specific scenario. If, however, you don’t trust your gut, contact your mechanic to remove and replace the rusted screw with a stripped head.