Originally Posted by corteasy
@YJ325i... If I had to do it all over again I would... It's been a extreme headache over a few days, but I feel extremely accomplished now that I got them out and painted. The drilling the Torx Bolts out was easy once I had the correct tool...the tough part is accessing the backside of the bolts on the Driver side window hinge... It is covered with gunk from the factory and is extremely difficult to take remove. Good Luck if you decide to go forward with it.
I went through the same thing with my 89, fortunately I learned some lessons.
1. Remove the insulation over the lower hinge bolts before you start working.
2. Be Gentle with the top bolts, Take your time and feel the bolts out.
3. Buy a wrench thats not magnetic. [Mine kept getting stuck to my speakers]
4. If you have big hands, get a friend with small hands to help.
When I did my 89. the 2 front top bolts stripped. I drilled them out and used an easy out, 1 came out and 1 easy out broke! The hinges where throw aways so I ended grinding the head off the one with the broken easyout.
after I finally got the head ground off, the backing plate fell inside the windshield. Fishing that up to where I could get ahold of it was a teadious and frustrating process. [Oh attempt to put the windshield down, roll bar torx stripped.]
After I got the backing plate back up and got a bolt in it to hold it I put to self tapping screws in it to hold it soaked the one with the grounded off head with PB Blaster and Vice Gripped it out. Then came the tough part, getting the new hings on while holding the backing plate through the 2 side top holes while I lined up the hinge holes with the windshield frame holes and the backing plate holes.
It was hell. My 88 however was smooth as butter.