Hi,

I was in the same exact situation as you were just last week. I attempted to get the back torx screw off of the thermostat housing only to severely round the head. I thought that the Craftsman torx bit socket with ratchet extension was good enough to get it out. But it seems that attacking that screw at even a small angle off center dooms you to rounding the head. So the following are my suggestions:

1. It sounds like you didn't round the head of the screw too badly. I'd suggest getting one of those high quality pencil-like torx bit sockets so you can get at the screw head-on without using an angle.

2. Or if you find that the head is rounded so badly that you can't use a ratchet, then you may have to end up either cutting the head off and/or drilling the screw. Unfortunately, I had to resort to this option. Fortunately, I had someone knowelegeable to help me so to save me the indignity of going to a dealer/shop. Disconnecting the fuel line will give you enough room to do the cutting or drilling.

When you get the screw out, for gods sake, don't replace it with another torx screw!! Use a hex bolt. :)