Lincoln/Mercury Repair: problem removing 91 Lincoln starter, replacement bolt, bolt heads

Question
Thanks for the info so for.  I'm looking for advice on things to do to make it easier to remove the bolt.  The threads themselves were fine on the one I got out, it's the bolt heads that are rounding out or stripping.  I guess I should have been more clear.  I sprayed with WD40 and am going to let it soak, tap it lightly, spray again, and leave over night.

I bought some new bolts from the local auto store that deals in high quality parts.  They are 5's, so I believe they will do.  I can barely get my hand and a 1/2 wrench up to the bolt.  My Craftsman socket and ratchet won't fit.  Any more advice?

Thanks,
Johnathon
-------------------------

Followup To

Question -
Greeting Sir,

I have a problem that hopefully you will be able to advise me about.  The starter on my father's 91 Lincoln towncar died.  He got another one and asked me to install it.  I believe that it is a 5.0.

I get under the car and put a 1/2" socket onto the bottom bolt,turn it counter-clockwise, and the bolt strips out.  After about two hours of work using vice grips and a Irwin set of damaged bolt removers I was able to remove it.  I still have one more to go, and am afraid that it may strip out as well.  It is in a position and angle so that if it does strip, I will not be able
to remove it.  Do you have any advice or ideas that could help me?

The bolt is threaded its entire length.  It had a lock washer under the head as well.  The bolt steel was incredibly soft. The upper, still attached, bolt has threads that run through the
attachment point and extend into the air for a little under a 1/2" (guessing by feeling the free threads).  I went to two different auto stores and the replacement bolt they showed was only threaded on the end.  Does this sound like someone previously replaced the factory bolts with cheap bolts for some reason?

Thank you for your time,

Johnathon

Answer -
HI Johnathon,

There is no easy way to do this, but removing the bolt won't be the cause of stripping it. If it's stripped, then it was done by the installing tech. This might not be the original starter and it's hard to say what the person did or didn't do that installed it previously. I suggest going down to your local Ford garage and hit the parts department up for the right bolt set. Under $5.00. It is entirely likely that if the person that installed the starter previously lost the bolts, he may have used the wrong bolts to re-install and it sounds like he used some pretty crappy hardware. If the bolts that are in there are as soft as you mention then the threads in the block should be ok. Cast Iron vs. Crappy bolts. Though when you go to install the new, proper bolts they might go in a little snug. Personally, I think you'll be ok once you get the other one out. They do make a thread chaser that you might use to clean up the threads in the block and this might help. Make sure you get the right one or you'll be in a world of hurt if you choose to do this! Good luck!

Answer
Ah, I see... Well, here in the garage, my R&R tech tells me he would start removing the bolt with a pair of vice grips. Then would hammer on a 12 mm or 1/2" socket and the rest is air wrench. You might try a longer extension and try getting a better angle from futher back. Otherwise, you'll need a nice, soft pair of vice grips! Of course, these guys have swivels and nice trick tools. It stinks, but I'm afraid there's no easy way. Sorry that whoever was there before you wasn't thinking of the guy behind him...