4.5 is too big and apparently 4 is too small. 5/32 too small. Wtf. Anyway, what do I do now? Drill it? Weld the alan to it?

How far is it in? IF the right screw was used, you can get needle nose vice grips on it.

I can get at it with a vice grip. I don't have a needle nose vice grip. Might need to get one.

Try tapping in an easy out, it shouldn’t be that tight. If’n that fails you can drill it out, be sure to get the proper cone screws prior

Good luck

You can bang in a usa sized allen on a 3/8 socket after soaking it in pb blaster overnight


Then of course replace the set screw, plenty on the shelf

I wish I had known before my last order that I was going to need one...

For a SS trans equipped car, buy 2. I would buy 4, pay shipping 1 time and not worry about it.

Wait to order until you have your whole list..
Bang in another Allen or a Torx bit on a socket.
Heat lightly with a propane torch (careful, fuel lines adjacent)
It may have had locktight on the threads, heat will melt it.

Excellent suggestion!

A little heat and a high quality extractor did the job easily. Thanks for the suggestions people.

One more suggestion: Try and get a set of the conical screws with the square head. They have a hole for safety wire (spelled reusable) and they don't rely on the socket as a installation feature. I tried searching for a part number but struck out. I got mine from Al when he ran PartsHeaven. I think they are early 911.

Grab a torx bit just a little too big for the hole. Hammer it in till it seats. Unscrew. Insert new cone screw. Buy 5 extra for later!

I tried the torx and the alan but it was not working. I decided it was about time I had a good set of extractors so I spent some money on that. I really think the heat was the key. If I had hit it with some heat first I probably wouldn't have stripped it. Somebody put some red locktite in there. I know, cause it was me. Fing DACO. And people on here warned me about exactly this problem but I was so frustrated with that cone screw loosening up. I have a big bottle of blue locktite now.

And a couple of cone screws on their way from autoAtlanta.

I love the sense of humor

Back to the original question, I sometimes got luck with sloppy or worn Allen head bolts after wrapping the wrench with a layer or two of aluminum foil.

Agree 100%. The square head ones with the safety wire hole are all I use. Funny thing is that I got all of mine from trading local 911 guys for allen head ones they wanted to "upgrade" to. I first learned of the safety wire when I bought my 68 912 years ago and fixed a sloppy shifter by tightening the very loose bolt. Make it snug and one nice wrap with safety wire around the coupler and you are set. Simplicity is elegance.