HELP Please! Broken bolt in hardtop liftgate hinge

[El-Jefes-Red-Rubi]

Ok. So I broke a bolt off while placing light brackets on my hardtop. It was the outside left so the access panel wasn’t helpful. I had to slowly cut off the bolt using a dremel wheel. For those that have had this issue it’s a fairly easy fix. (Pics attached)

Step 1. Drill a pilot hole through the open hole in the hinge through the interior (keep it level)

Step 2. Using a 1.25” hole saw slowly cut a hole in your hardtop interior. (Patience…Felt weird to do)

Step 3. Use a new bolt with lock washer to replace the broken bolt.

Step 4. Use a rubber/plastic cap to seal the hole. The caps I used were harder plastic than I thought so I had to cut off some of the ribs to allow the cap ribs to flex.

I’ve since painted the new bolt black to blend in.

Looks fairly factory

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[daveprice7]

Man.. what a kick in the nads. I just had one of my hinge bolts twist off while removing it. How does that even happen? Are these things made out of cast aluminum or something?

I sure don't want to keep using these weak-ass fasteners and play bolt roulette every time I take the back glass off... Now I gotta figure out where my screw extractor set is and hope for the best...

 

[Cpt_Caveman]

Did anyone who pulled these get the dimensions for a stronger replacement bolt? Want to figure it out before I start pulling and be ready to replace as I go

 

[DaltonGang]

What kinds of cheap a$$ bolts is FCA using on these Jeeps??

 

[OregonJeep]

Just happened to myself and I also
Tried a extraction tool and broke that.

who has had luck here? Please share.

 

[El-Jefes-Red-Rubi]

If you look back on this thread… Easiest way is to drill through the inside of the hardtop to access the broken bolt/stud. The use a plastic automotive cap, sold on Amazon, eBay, etc to plug the hole.

 

[Javi_JL]

Does anyone know the part number for the replacement bolt? Cant seem to find it.

 

[tker32]

Well, while I feel bad for everyone, I'm glad I'm not alone in my misery. Pretty much the same details as everyone else. I was trying to install the Topsy bracket and snapped the right bolt on the left hinge. I tried using an extractor without any luck. While doing that, I stumbled on a less nuanced and technical solution...use the BFH. I put a junk bolt on top of the sheered bolt and hit it with a hammer. I was able to bend the backing bracket enough to give me room through the grommet that I can fit my hand in to hold a washer and nut and will run a new bolt in. Like I said, not the cleanest of fixes, but it should get the job done.

Does anyone know if it's a 6mm or 8mm bolt?

 

[Terrymo]

Well, while I feel bad for everyone, I'm glad I'm not alone in my misery. Pretty much the same details as everyone else. I was trying to install the Topsy bracket and snapped the right bolt on the left hinge. I tried using an extractor without any luck. While doing that, I stumbled on a less nuanced and technical solution...use the BFH. I put a junk bolt on top of the sheered bolt and hit it with a hammer. I was able to bend the backing bracket enough to give me room through the grommet that I can fit my hand in to hold a washer and nut and will run a new bolt in. Like I said, not the cleanest of fixes, but it should get the job done.

Does anyone know if it's a 6mm or 8mm bolt?

Wild ass guess…M6-1.0x30. I’m not removing mine and breaking it to find out ?

 

[tker32]

Wild ass guess…M6-1.0x30. I’m not removing mine and breaking it to find out ?

A 1/4 inch x 1 worked for it. It was a pain to get the nut on through the groomer opening, but I used a nylon one so it won’t work loose and don’t ever plan on removing those bolts again

 

[VFTEX]

I stumbled upon this thread while searching for Topsy brackets to use for my lift. now I read above that several people have stripped off the bolt trying to install what should be a simple solution. I have concerns now to go this route. The bolt is obviously not intended to be a mount point for 2 different things.. Anyone run into trouble just running a 2 or 3" strap through the top? I know it will press on the weatherstripping, but how bad could that be? I'll take that before a stripped bolt if minimal issues. 3-4 bolt breaks just on this forum, there has to be many others... maybe not a good point to mount this? Or an anomaly of bad bolts?

 

[SlickRicksWilly]

Been running 1" wide straps through the top for about 6 years, on and off multiple times a years without issue with weather stripping.

 

[ForgottenTaco]

I bought a pool noodle, cut it into quarters to put over the weather stripping where the strap sits. Probably an unnecessary step but it’s peace of mind and only cost me a dollar.

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