The metal on the one fitted seems to be made of cheese and has rounded off. Any tips for removing? Have tried vice grips and it just won’t grip.
Shall I just get a replacement caliper?
Try soaking it in WD40 for an hour, then try using screw extractors.
I have used these successfully before.
If all else fails, then drill it out and re tap it.
But if you’re not confident at this, then it looks like you’re on the new calliper route…
Heat is often your best friend with seized threads. Great tool to have is a small chefs blow torch (that is a butane torch, small in size, used for caramelising etc, not a flame thrower for little people who cook).
You can get very localised heating with the fine flame. Just be sensible as brake fluid (as well as many other bits of your car) is quite flammable.
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A few years ago I borrowed a nut&bolt extractor set that looked very much like this one. I think it’s tough enough (CR-MO) and likely has a small enough size to fit. Check first!
I used my little Bosch impact driver on the lowest setting to minimise the risk of shearing off the rusted manifold studs and let it tap away until the nuts finally came off. Patience is a virtue here.
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Thanks all for the replies! I have “invested” in some opposite thread bolt removers from screwfix, similar to the ones in the first reply, but only £3.50. Will give them a try a try tomorrow, if not I’ll try those other ones in the last reply!
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Hopefully it all works out ok👍🏻.
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You need to hit it end on with a hammer. Often the shock breaks the bond. Fluids never work, heat does.
The best thing is often a cheap old socket which is one size too small, hammer it on (after doing the above) then gently rock the screw backwards and forwards just a small distance until it lets go.
If all that fails, new caliper time.
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If all else fails, hammer a hexagon nut onto the valve then weld it on. The heat will break the bond and you can then use a proper sized socket on it.
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Even though heat or shock might work better, fluid can work too some times. Just need to use something better than WD40 
Its a tough one which most of us have had to deal with at some point in time.
Use central pressure to release. Side pressure from a traditional spanner or mole grips will likely lead to the nipple snapping off.
Heat, Easol, plusgas or similar and a smaller socket hammered on would be my method. If you have a welder the idea of welding a nut on is good too.
Before going to too much effort make sure the caliper is worth it:-)
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