How to Safely Remove a Rusted and Damaged Screw from a PCB

When repairing electronics or circuit boards (PCBs), it's common to encounter screws that are rusted or have damaged heads. This is especially true for devices that have aged or were used in humid environments. If you try to remove such screws forcefully, you might end up damaging the board itself—leading to higher repair costs or irreversible failure.

An instructional illustration showing how to remove a rusted and damaged screw from a PCB using super glue and a screwdriver.

In this post, we'll break down how to safely remove rusted and stripped screws from PCBs. Whether you're a beginner or a seasoned technician, you'll find detailed step-by-step instructions, tool recommendations, and critical safety tips to guide you through the process.

 

 

1. Assess the Screw Condition

First, check the state of the screw. Determine which of the following situations applies:

  • Partially stripped head: Cross or slot head is rounded but still visible
  • Completely damaged head: Head is broken or worn flat
  • Rust-seized: The screw thread is corroded and stuck in place

Proper assessment helps you choose the right method and tools.

2. If the Screw Head is Partially Intact

The rubber band + screwdriver trick is often the safest and easiest method. Place a rubber band over the screw head and press the screwdriver down firmly while turning. The rubber helps regain friction in stripped areas.

If that fails, try super glue. Drop a small amount of glue into the damaged head, place a screwdriver in position, and let it harden for 5 minutes. Then attempt to turn it slowly to extract the screw.

 

 

3. If the Screw Head is Fully Destroyed

Here are a few methods to try, in order of increasing complexity:

① Use Needle-nose Pliers

If the screw shaft is slightly exposed, grip it tightly with pliers and rotate counterclockwise.

② Apply WD-40

If the screw is heavily rusted, apply a tiny amount of WD-40 or rust remover and let it sit for 5 minutes. Make sure the chemical doesn’t spread over the PCB.

③ Carve a New Slot

Use a small awl or precision drill to create a new slot on the head. Then, use a flathead or Phillips screwdriver to unscrew it.

④ Use a Screw Extractor

Easy Out bits are designed specifically for damaged screws. Drill a small hole into the screw and twist the extractor in reverse to pull it out.

⑤ Heat with a Soldering Iron

Lightly heat the area around the screw with a soldering iron to loosen any oxidation or adhesion. Avoid overheating, as it can damage the PCB.

 

 

4. After Removal: Inspect and Reinforce

  • Check for circuit damage: Inspect surrounding traces and pads
  • Fix worn screw holes: Use plastic anchors or epoxy if threads are damaged
  • Apply anti-rust treatment: Lightly coat the new screw with lubricant before installation

5. Prevent Future Rusting or Stripping

To avoid this problem in the future, follow these practices:

  • Store PCBs with silica gel or in dry boxes
  • Pre-lubricate screws before use
  • Use stainless or brass screws instead of standard steel ones
  • Apply silicone coating to the PCB if the environment is harsh (avoid heat zones)

 

 

Conclusion

Damaged screws on circuit boards are a common but frustrating issue. By following the proper diagnosis and applying methods in this guide—from friction-based techniques to tool-assisted removal—you can safely handle such repairs without risking damage to the board. Always check your results and apply anti-corrosion steps when reinstalling screws to ensure long-term reliability.

Keep the recommended tools on hand and consider preemptive anti-rust measures if your devices operate in challenging environments. A few precautions go a long way in preventing screw failure.

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