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Topic Review (Newest First)
11-12-2012 10:44 PM
Carralo1 When removing torx headed bolts

1 Be prepared to drill out and retap if attempting to remove
2 make sure you have the right size.
3 put the torx bit into bolt head and tap with hammer. I use an impact nut driver it is called. It works perfect for this.
4 Use an impact!! Don't use a ratchet or breaker bar, it will strip 80% of the time.

Just some hints I have after Already gone through things like this in the past
11-12-2012 10:15 PM
Vic Lagina I am about to relocate my side mirrors to the windshield hinge on my '89 YJ. I hope I can get it done without going through what you went through.
03-18-2012 08:23 AM
Master4th
Quote:
Originally Posted by corteasy View Post
@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.
03-18-2012 01:29 AM
CaliWrangler @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.
03-17-2012 10:48 PM
YJ325i WOW, I was going to put fog light brackets on my ws brackets, but now I'm like....hmmmm don't know if its worth it. man I feel for your headache
03-17-2012 04:03 PM
CaliWrangler Thanks for the heads up, I'll check out my Local Hardware store and see if I can find something similar. I just want to make sure they fit flush in the Windshield/Hinge mount. I don't wont it looking too funny sticking out or anything like that. Now I have to figure out how to get the ones off the door hinges that are stripped! I believe those are threaded in so they just won't fall out the backside.
03-17-2012 03:50 AM
Dutch 95 Man.......I'll tell ya, I'm soooooooooo glad it worked, (I was beginning to doubt how I did it). A step bit is a great idea I hadn't even considered, and I have like five step bits, DUH!!! As for the bolts, get some hex drives with the same thread pitch. You've already learned how well Torx drive works. You can even get then at Lowe's or Home Depot.
03-17-2012 01:16 AM
CaliWrangler LoL, Ya it was pretty awesome... Drilled straight through the bolt!!!...I finally got the dash off (Well Pulled Back A Little)...I went to my local Auto Parts store and bought a "Step Drill Bit 1/4" - 3/4" and drilled off the heads while holding the backs with a pair of vice grips... It worked like a charm! Now I gotta buy ten torx bolts for the Windshield Hinges... Those little things are alot pricier than I thought...LOL!
03-17-2012 01:11 AM
Dutch 95 Sorry about that, I went from memory on the first size, but I did it almost 9 months ago. I gotta say, you must have drilled straight. LOL Use a little bit bigger bit, it will break off. 11/32 should do it. If you would let me know that the 11/32 works, I'll edit my picture accordingly. There can't be much holding that bugger on.
03-16-2012 12:53 AM
CaliWrangler The joys of jeep ownership!!!

I been trying for the last 2 hours to take out the stripped bolt! No DICE!

I think I may have made matters worse... I actually drilled all the way through the torx bolt/screw( thanks for the diagram dutch) The head never came off.... So now it's just hollowed out! All because I wanted to paint the hinges black!!! LOL... I'm trying to learn, so I guess this is just a learning experience I will look back on many years from now!

I noticed another thread on the board as well so I'm keeping a close eye on that one too.
03-15-2012 09:17 PM
DILLIGAF Those nuts were extreamly difficult for me to reach, I took a piece of 3/4 conduit and made an extension handle for a boxed end wrench it made holding the nut easier, especially for re-assembly, once you can get those stripped bolts out,
03-15-2012 07:55 PM
Dutch 95 This is how I did mine. You will probably only have to do step one, because you have a nut on the other side. Once the head comes off the nut will fall off the other side.

03-15-2012 07:05 PM
Master4th Yeah bottom ones have a nut, just reach up behind the speakers.
03-15-2012 09:07 AM
cozeinlb You can try and drill them out. There was a thread on here a couple days back with details and drawings. I believe it was a 5/16 till teh head comes of and then 1/4 thru the rest. Just make sure you get good drill bits or you will be breaking them or they won't cut. Those bolts are really hard.
03-15-2012 08:10 AM
LoveLEE143 There is a nut in the inside. You will have to reach behind the dash behind the speaker. As far as stripped bolts I had to take me Jeep to someone with a welder and heat the bolts. Then quickly use a pair of pliers to get those bolts off.
03-15-2012 03:19 AM
CaliWrangler
Torx Bolts on Frame/Windshield Mount...Sorry I know my Questions.

Hi Everyone...again. Thanks for all of the help so far with my other post. I ran into another problem working on the NEW (well new to me) YJ!

I removed the Windshield (after reading threw some threads figured out how to disconnect the Wiper Motor), as I was trying to remove the Torx Bolts from the frame of the YJ to take off the hinges(going to paint them an awesome color),I ran into a couple problems....

Problem #1... A few Bolts will turn and turn and turn and turn and turn in both directions but will not come out... How would I go about getting those out?

Problem#2... The bolt is completely stripped by PO. How would I go about removing those?

Any help is greatly appreciated. I have attached a photo.

Thanks

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