Removing middle gear torx screws

I'm having trouble removing the middle gear torx screws so that I can split the engine cases for a starter clutch rebuild (X650K). I've tried drilling out the staked portion of the screws per the shop manuals but haven't had any luck: drill bits keep breaking off (black oxide, cobalt, no dice).

Knowing the bearing retainer plates are inexpensive to replace, can I just remove the screws with an impact wrench and the right torx socket (T40?) without damaging anything else but the plates? Or is this a bad idea?

Thank you!

 

Yes. Do that. The retaining plates shouldn't be damaged in the process, but you might damage the screws.
I prefer to use a carbide burr on a rotary cutting tool to remove staking, but cutting the stakes is not always needed.

 

Thanks k-moe, I hadn't thought of that, and do have a Dremel with carbide burrs. I'll give that a shot and see how things go.

 

Be sure to thoroughly clean all of the steel parts in that area after using the burr. The chips will tend to be magnetized as you cut.

 

Quick update: k-moe's suggestion works like a charm, ground away the staked portion of each bolt head (and some of the surrounding retainer plate along with it) with a carbide-tipped rotary tool and a quick blast with an impact wrench did the trick.

Also, just for posterity, the Torx bit is a T40, and of all the hardware and home and garden big box stores only Harbor Freight appear to carry impact-grade torx sockets in-store (all others are online only), and even then I had to buy a set of 8 or 10 (not sold individually).

Thanks again for your help.

 

Looks like someone has a few torx sockets for sale!

 

did you try a auto parts store?

 

I did try the larger Napa location in the area, no dice there, but that was it, I had been wanting to check out Harbor Freight for a while anyway and figured they'd have it.

 

my bubble is burst