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Old 08-09-2010, 09:47 AM
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Roll Bar Removal

Are there any tips on the sequence to remove them and tips to get those nasty torx bolts out? I need to do some floor repair. Thanks

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Old 08-09-2010, 09:56 AM   #2

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I took a 3/8" drive torx socket (T-45 I think) and pounded it into each of the torx bolts till it was all the way in there. I gave it an extra whack or two to help break it loose and then put the ratchet to it and got them all out. I did have a problem with one of the torx bolts getting stripped out inside so I took a dremel tool and cutting wheel and made 2 cuts so that it was in a rectanglish shape(2 parallel cuts on either side of the threaded part of the bolt). Then I used some vice grips to twist it out.

I didn't do them in any particular order as far as removing the bolts but I did remove the bars that go to the windshield first. And you'll need to fold the windshield down to get those bars out.

You are probably going to have to do a bit of prying because two legs of the cage that go to the floor right behind the front seats are glued in with some tar like stuff.

2000 TJ Sport
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Old 08-09-2010, 11:56 AM   #3
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I sprayed all the bolts with PB Blaster for a couple of days everytime I would think about it. I then attached the torx bit to my impact wrench if I could not break it loose. If that did not work I used a pull handle and then my air rachet. Good luck.
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Old 08-09-2010, 07:59 PM   #4
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Get some good Torx bits. (T-45 & T-50)
Not the cheapo one piece bits from the auto parts stores. You'll need the good two piece bits from Craftsmen or Snap-on. They are much stronger and can be used with a breaker bar without stripping. Put the bit into the Torx bolt head and give it a quick smack with a hammer. Then use steady even force with a breaker bar until the bolts turn. Don't jerk on them.
For really stubborn bolts you can apply some heat with a torch to the area from underneath.
Remove the inside windshield bolts first and lay the windshield down on the hood.
Then remove the roll bar floor bolts front and rear.
Finally, lift up on the rear braces and rock the entire roll bar forward. This will separate the sealant between the roll bar feet and the floor.
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Old 08-09-2010, 08:05 PM   #5

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If the torx strip out weld a nut onto them and use a ratchet or air gun to remove them. The heat from welding the nuts on will loosen the rust and you can replace them with stainless steel hex head bolts you can buy at any bolt supply shop.
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