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.
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.