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Old 06-25-2008, 05:16 PM   #1
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Solution to removing Safety Torx Screws with bent pins

I came across a problem while trying to remove the forward roll cage bars that connect the rear cage to the front windshield on my 2004 Wrangler. I inserted the safety torx wrench (bought from a local autozone), attempted to loosen the safety torx bolt, and the wrench slipped out.

After inspection, I realized that I had just bent the safety pin (inside the safety torx bolt) downward, thus prohibiting the wrench from being inserted again. To fix it, I did the following.

1) bent the pin back upwards as far as I could using a flat head screwdriver as a chisel and a hammer (caveman approach)
2)Placed the safety torx wrench over the pin and the bolt, and hammered it until the pin shaved down enough, so the wrench could be fully inserted to allow bolt loosening.

Lesson: Be sure that your safety torx wrench is fully inserted into the bolt before applying a torque to loosen the bolt.
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Old 06-25-2008, 05:26 PM   #2
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Old 06-25-2008, 05:27 PM   #3
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I made it a point of using a punch pin to snap all those little security pins out entirely. Just a tap or two with a hammer and smaller diameter punch pin from the side and they're brittle enough to just snap off and cause no more problems.
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Old 06-25-2008, 11:06 PM   #4
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The lesson of that i think is torxs suck BTW autozone stuff is cheap quality and they get screwed up easy, get something good so you dont end up damaging the bolts because those are tough to undo once stripped.
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Old 06-26-2008, 12:16 AM   #5
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i have a snap-on automatic center punch i use to break the centers out of those retarded "safety" torx bits.
just a couple quick hits and those pins shoot halfway across the shop
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