I thought you used something special to remove the screws.

 

I think O'Reilly has them as well.

 

Under ideal circumstances a torx bit will work just fine. So far, it appears that most of the folks who attempted this with their "torx set" wound up stripping out the bolt. I did the same thing, even though I had the right size torx in there. I needed to use those stripped bolt adapter (10mm) to get the bolts out. Luckily Ragu found them, and I was able to get the bolt out. One of them came out normal, with very little effort. The other one stripped out almost immediately.

 

Mine are so far undamaged, and I've only tried using the torx driver. But will get the power grip as a backup for my next assault. Thanks for the information.

 

If you don't need it now I am sure it will come in handy later.

 

Yes, thanks for bringing this up. That is where I found them, at O'Rileys. Those worked so slick I wouldn't mind doing it over again!

 

I bought a Irwin #394002 at AutoZone, worked great. Problem now is I can't get my big hands back in there to reinstall the KSB with the spacer......

 

i used the technique the guys stated by putting a bit of grease on the washers that push the spring out. Spring tension is the big part of the issue, I'm sure. Don't you have an Asian people in your neighborhood ? I hear they have small hands....

 

Haha I only wish I had some help. To compound my problem is the power steering reservoir is mounted close. I'll get it, but had to step away from it today.

 

Success!
I removed the solenoid from the KSB and found a longer bolt and cut it's head off. Screwed it in like a stud. This acted as a guide for the forward hole. Used grease to hold all the bits and pieces together and got it all stuffed into the hole. Started the new screw in the rear hole and pulled it up pretty close. Stuck a rubber hose on the stud and carefully unscrewed it and quickly replaced it with the other new screw before messing up the alignment. Pulled everything tight using T30 wrench I made. Had a struggle getting the 8mm line reconnected which surprised me a little as it is very accessible. Issue I think is that KSB is mounted at a slight angle. And of course the real issue is I'm pretty near blind and can't see details. I'm too old for tedious stuff. It took a few tries to get the engine started, but after driving about 10 miles (around the block) it is running smooth. Going to install a 4" pipe, harmonic balancer sensor, serpentine belt tensioner and oil/filter change Tuesday. I'll do this work at a friends shop where I got a lift and help if needed. Thanks for all the suggestions, it all helped. My backup plan was to use studs and just slip it in and tighten the nuts. This might be a solution for someone with the same poor luck as I had with this install..

Thanks,

Follow-up: Drove to town and back, about 50 miles. Very impressed. Throttle feels lighter and cruises at 55mph without the slightest of strain. This sweet spot was just above 50 mph before and now it all feels like it is in the sweet spot. This is a good mod for my stock truck.