...and now I can't get it out.

I guess I wasn't paying attention when I installed my DP, and the curved cutout in the washer that lines up with the weld in the DP was actually not lined up properly. I torqued both DP bolts to spec. Well, now I have to pull it off to pass smog (again), and after I got one bolt off, I couldn't get the last one off. When it looked up there, I saw that the washer was spun around 180 degrees, and this is probably putting a side load on the bolt. I cannot get it free, and I'm asssuming things are worse because of the spring. I can't even get it off using my 18V impact wrench.

Anyone have some clever ideas? I was thinking that maybe I should look for some kind of spring compression tool to relieve the bolt from all fo the spring force, but I've never seen anything for springs that small.

 

Finally got it out after soaking it a couple of times in PB Blaster. Hit it with the impact wrench for quite some time, then got better leverage with a really long bar. Yeah, this bolt needs replacing...

 

Nice job. Thanks for updating your results

Maybe some Anti-Seize on the return trip

 

How did those 2 threads strip and not the rest of the tip?