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[Gaffers]

I am not sure that removing rad will give you any better access.  As mentioned by amba, if you put the other two nuts back on they will reduce the load on the last bolt and will make it easier to come out.  Make sure the groove you have cut is very deep, get your hands on a dremmel if you can, then with a slot screwdriver attachment to your wrench give it some sharp turns/hits.

I trust that the aux belt is still on

[Mart280]

Thanks Guffer I have done all that and the bolt is still stuck fast, Iv'e just had a gas bottle on it with no joy although rain has just stopped play.

[albitz]

Chop its head off,then once the pulley is off grab the stub with a pair of molegrips and remove it.

[amba]

Wont be a lot of thread left,Albs,as that water pump pulley is only thin metal.

I would keep up the plusgas and gently hitting the cut edge with large screw driver in an attempt to shock release thread.

Could always give it a good warm up with a MAP gas torch as that will give direct heat

[Mart280]

Thats a good Idea Albitz and will be my next move.

[Mart280]

Wont be a lot of thread left,Albs,as that water pump pulley is only thin metal.

I would keep up the plusgas and gently hitting the cut edge with large screw driver in an attempt to shock release thread.

Could always give it a good warm up with a MAP gas torch as that will give direct heat

I've had a gas torch on it already and been wacking it plenty, it really doesent want to move.

[albitz]

Do the bolts protrude through the rear of the water pump flange at all ? If they did it might be easier to grip the end of the bolt at the rear of the flange and get it moving,once the pulley is off .
Cant remember off the top of my head how much clearance is there without the pulley.

[robson]

Sounds like its time to get someone to weld a nut onto the stub thats left or try to drill the stub and use a reverse easy out ,if its that tight however  you may break the easy out and then you will have more problems.

[robson]

Which pulley is it that you cant get off?

[robson]

Sorry you said earlier that it was the power steering pulley is that correct?

[robson]

If you do get welding done check on here what you need to disconnect prior to welding

[Mart280]

Sorry you said earlier that it was the power steering pulley is that correct?

Yes thats the one, as for welding there isnt much left of the nut to weld it to.

[amba]

Sorry ,just re read the full post and see the problem bolt is on the power steering pulley and not the water pump as I had first thought..although my approach for either would have still been the same.

If it is going to get cut as a last resort then for the extra effort and ease of getting the broken bit out afterwards,you may as well just remove the entire power steering pump and work on it in at a better angle held in a vice as drilling it out will be a whole lot easier and probably avoid damaging the pump with the added cost of a replacement afterwards.

[terry paget]

What a nightmare! Just for a leaking water pump. If the stuck screw were in the water pump you could grind off the head because you will change the water pump any way. It's a mystery how it came to be overtightened, because you can only tighten it with the belt on, by which time you have put it in finger tight. Could it be too much loctite applied by some earlier mechanic?

Is there room to get a 90 degree drill attachment in to drill the head off the screw?

[robson]

Thats why I asked which pulley it was  Amba beat me to it take the steering pump off so that it can be worked on in the shed, garage, kitchen table.