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Old 11-17-2009, 01:51 PM   #1
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Stripped Bolt on Tailgate

Hi all,

So my jeep is going to the garage for the winter, where I plan on taking different parts off, fixing them, and putting them back on.

The first section is my tailgate, but one of the torque bolts on the hinge is striped. So I get a cheap bolt extractor, and it breaks INSIDE the drilled out bolt.

What the hell do I do now? I returned the crappy extractors and got some better ones (hopefully they won't break so quickly) but when I try to drill out the hole again I can't get through the original broken extractor which is in the way.

Do they make drill bits that will go right through hardened metal? Has anyone taken their tailgate apart, can I take off the inner panel and somehow grab the bolt from the inside with pliers or something?

Any suggestions appreciated. I just want to fix up my YJ!!

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Old 11-17-2009, 01:54 PM   #2
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Easiest way now is for you to have someone with a welder weld a bolt to the stripped bolt. Remove the bolt....removes the torx.

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Old 11-17-2009, 01:55 PM   #3
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Weld a nut to the end of it and turn it out.
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Old 11-17-2009, 04:39 PM   #4
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any options that don't require welding?
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Old 11-17-2009, 05:53 PM   #5
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I dunno about hardened steel, but I've certainly drilled through alot of bolts. Get a bit that is slightly smaller than the head of the bolt, drill it out. Head comes off one side, bolt slides right through.
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Old 11-17-2009, 08:45 PM   #6
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You might be able to break the easy out with a hammer and a punch. Give it a good hard whack.
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Old 11-17-2009, 09:41 PM   #7
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I agree with distorted. Save yourself the heartache and have someone weld the bolt on.
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Old 11-18-2009, 03:49 AM   #8
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Or if you don't have anyone that can weld but you do have a couple of bucks you can go out and get either of these depending on if its a torx screw or a bolt

Screw: GRABIT 3-Piece Drill Set - PR-5823 - Smarthome

Bolt: Craftsman 10 pc. Damaged Bolt/Nut Remover Set, Low Profile Bolt-Out

Hope that helps

Edit: I'm an Idiot and completely didn't comprehend your post wow 5 am and just going to sleep makes you weird... sry
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Old 11-18-2009, 09:44 AM   #9
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Edit: I'm an Idiot and completely didn't comprehend your post wow 5 am and just going to sleep makes you weird... sry


Are you ok vaultzz.
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Old 11-18-2009, 10:20 AM   #10
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I've tried just about everything for this exact issue. Welding a high grade bolt or a nut onto the head of your Torx bolt is really the best solution.
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Old 11-18-2009, 07:28 PM   #11
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So I got a pic of what am dealing with.



As you can see I attempted grinding some grooves into the bolt, so I could hit it with a chisel or the sort, but I ended up hitting the hinges a little.

You can see the broken off bit inside, which is/was the bolt extractor.

So, anything I can do? Isn't there a drill bit that I can use to drill this out, and then try using an extractor again? I bought these craftsman extractors, but they seem to be too thin...unless I can re-drill the bolt out, getting what is in there now out, and then I can use the smaller extractors.

Thanks for the help,
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Old 11-20-2009, 06:20 PM   #12
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There really isn't easy way of getting the "easy out" out. I would try to take a propane torch and heat the bolt up....shouldn't take more then a couple of minutes no need to get it red hot or anything....then take a small cold chisel and tap the bolt out using the slots you ground in it.

If your set on trying to get the "easy out" your going to have to spend a little and buy yourself a carbide drill bit.

I will say that I have had alot of luck on both my 88's and my 90 yj just by heating the bolt head up for a few minutes with a propane torch. Matter of fact just got done replacing the windsheild hinges and had to do this very thing. Hope that helps

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