I was wondering if anyone could give me some help with a stripped TORX head screw. I was removing the windshield hinge upper screws to install some KC light brackets and got all of the screws out but one. It is messed up now and I could use some insight on how to get it out. I know maybe an extractor or easy out, but maybe someone has a trick. I have bought replacement screws for all of the ones I am removing so it will be good as new once I get this last one out. Thanks for the advice.

I tried ez outs and snapped them. Then had to resort to a masonary bit to drill the ez out. In the end we were successful. No trick, just lots of drilling.

Drill baby, Drill.

search it, this was discussed way back. From memory, the person used over sized torx.. hit it in there and undid it with air gun or something like that. I wish i could be more helpful but it was long when i last saw this thread.

use a hack saw to cut a slot in the top of the screw and then use a large flat blade screw driver to remove it.

whatever you do DONT REPLACE IT WITH ANOTHER TORQ SCREW. use anything alse

i had the same trouble...i just drill it out and replaced the broken hinge and then siliconed the hole shut......the other bolts will hold it good enough

How about tapping the head at an angle with a chizzle slow and carefully until it starts turning, otherwise, drill and clean

try tacking an impact wrench (the hammer to turn kind) bit into the torx use the tightest fitting allen bit and start swinging that hammer! maybe a heat up w/ a torch and a cool down wouldnt hurt... or drill drill drill drill.

too bad that doesnt work. I work in a metal shop and have broken few taps.. you hit that thing, you're done and its locked in place.

Place a nut on it and weld the inside of the nut to the top of the Torx and then use a wrench to remove.

rkwfxd hit it right, just like my idea but better!!!

No magic potion here, I've drilled them out.

use a grinder to smooth opposite edges on the torx head and then try to use an adjustable wrench to get it off.

I would also say weld a nut to it if you have access to a welder.

I finally drilled it out and was able to tap some new threads and get the bracket installed. Thanks for all the tips. I really like the welded nut idea. I may have to keep this in mind for later wrenching. Thanks again.

Welding a nut or bolt onto the top of a totally stripped out bolt works really (!) well. Not only does the fact you now have a good head to get a wrench onto, the heat from the welding often breaks the bond between the bolt underneath and what it was screwed into. Half the time I tack-weld a bolt onto another bolt, it comes out so easily afterwards I used to think WTF? The heat generated from welding helps a lot.

On the windshield torx screws drill into the head with a drill bit that will fit into the head of a good torx screw of the same size. Drive the torx socket into the hole with a hammer and unscrew it.
jeeptoad 2004 Wrangler with new light bar