I recently destroyed my tail gate hinges and am planning on purchasing a couple new ones for about $70 bucks each. The replacement should be easy but those Torx bolts havent moved in 14 years... I already twisted my T40 bit and now need advice to unstick it. My bit wasn't exactly top of the line (Crescent set) but I dont have the cash to buy an entire new $300 set of torx bits from Snap On... Any suggestions of what strength/grade of metal I need to buy to get those things off?
These are the hinges I was going to buy, purely on price as I'm strapped for cash currently, if there is a better option I'm gladly open to suggestions.
I drilled a few of mine out. Use a bit a little smaller than the diameter of the bolt; the head will break off as soon as you're below it. Once you have the hinge off, you should be able to back the bolts out with your fingers (or possibly a vise grip). I replaced mine with Allen heads as the heads were exactly the same shape and I couldn't find Torx heads (and Torx is horrible).
Torx are great bolts. BUT you must use a QUALITY bit with them. And it must be fully seated. I love using a hammer driven manual impact wrench with them. The hammer drives the bit in solid just as the drive applies torque.
A good quality proper size bit helps but the ones on the hinges typically have a lock tight like substance and you need heat to get it released
To prevent/minimize paint damage you want localized heat and hear a good output solder gun (not a little iron) with tip directly on the torx head of the bolt works well. Once the locking substance is heated the bolts typically come out easily. Patience and a plan usually beats bruit force
I always use a soldering iron in the torx head of the screw to get it hot and soften any locktite that might be on the screw, then I use a manual impact screw driver (the kind you hit with a hammer) to break the screws loose. If the screw head gets damaged, then I use a center punch and hammer on the face of the screw to drive it counter clockwise. These methods have always worked for me and I have yet to be defeated by a Jeep torx head screw.
For $150 per pair you get heavier duty aftermarket hinges such as Exogates. I would imagine that's what he is going with.
Buy an impact torx bit and use heat to soften the red Loctite before removing the existing ones.
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