Tailgate Hinge Bolt Head Stripped

[cafecito820]

I know I can’t be the only one who thinks that the T40 torx bits on the tailgate reinforcement bracket are such a god-awful choice. Two of mine have stripped the heads, and this one managed to break the extractor but off inside of itself. Now I really have no clue how to get this thing out … the bits are extremely hard and even my cobalt bits won’t drill it out.

I even tried grinding an edge into it, and the freakin thing broke my grinder blade. I swear to god this bolt is made of whatever that precious mineral is in the Black Panther movies.

Does anyone have any other ideas for how to get this out? Is it possible to get at it from the other side somehow?

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[HK1s]

I have small diamond bits that I would do a slot very slowly.

I think you might need help from a shop nearby.

If you take off the trim piece from inside, some bolts are exposed. Could try that.

 

[The Last Cowboy]

Heat it up with a propane torch. But don’t keep the flame in one spot long enough to burn the powder coat.

 

[kah.mun.rah]

Weld a nut to the top of it and socket it out.

 

[Opus]

For me, and my limited tool selection, it would be time to hire a professional...

 

[GATORB8]

Damn, breaking ez outs sucks.

A “solid carbide” bit should work, but how about an impact screwdriver with a split flathead?

 

[CaJLMetalHead]

Torx are great for smaller stuff like electronics and avionics, panels, etc..... but for higher torque applications is simply stupid.. I don't get why engineers still choose Torx for such applications (ask any Harley guy who is trying to remove 5-year-old Torx bolts from the rear shocks of a Sportster... LOL)

although there are kits for removing stripped bolts.. I think the simplest option in your case is to weld a flat bar at an angle to the bolt so you can have enough torque to remove it.. then apply heat to the bar close to the bolt so heat transfers to the bolt.. then tap the bolt a couple of times with a pin punch tool.. and then proceed to use the welded bar to unscrew the pesky bolt

 

[Chrismeece74]

Same thing happened on my wife's Jeep. We took it to a shop and they used an easy out to take it off.

 

[jaardappel]

I know I can’t be the only one who thinks that the T40 torx bits on the tailgate reinforcement bracket are such a god-awful choice. Two of mine have stripped the heads, and this one managed to break the extractor but off inside of itself. Now I really have no clue how to get this thing out … the bits are extremely hard and even my cobalt bits won’t drill it out.

I even tried grinding an edge into it, and the freakin thing broke my grinder blade. I swear to god this bolt is made of whatever that precious mineral is in the Black Panther movies.

Does anyone have any other ideas for how to get this out? Is it possible to get at it from the other side somehow?

The exact same thing happened to me. I used one of these and a socket wrench to slowly back it out. It worked flawlessly on two of them. No need to drill since the bolt-head is already indented. You can pick them up from Home Depot or Lowes. I switched to a hex-head bolt instead and after tightening...hit it with a shot of black truck-bed liner paint around the bolt so it won't oxidize or rust.

Good luck. And yes...you can turn it from the inside (inside the guts of the door from the interior) with vice-grips but I wouldn't as you'd likely mess with the threads and it wouldn't come out from the front easily. This method is pretty much foolproof and my bolts looked exactly like yours. Crazy that they gave us those for the reinforcement kit.

 

[cafecito820]

The exact same thing happened to me. I used one of these and a socket wrench to slowly back it out. It worked flawlessly on two of them. No need to drill since the bolt-head is already indented. You can pick them up from Home Depot or Lowes. I switched to a hex-head bolt instead and after tightening...hit it with a shot of black truck-bed liner paint around the bolt so it won't oxidize or rust.

Good luck. And yes...you can turn it from the inside (inside the guts of the door from the interior) with vice-grips but I wouldn't as you'd likely mess with the threads and it wouldn't come out from the front easily. This method is pretty much foolproof and my bolts looked exactly like yours. Crazy that they gave us those for the reinforcement kit.

This is exactly what I was trying last night. The extractor bit snapped off inside the bolt. Yea… lol

 

[Steph1]

We just had that happen on my brother’s jeep a few weeks ago.

Just open your tailgate remove the inner tailgate molding/plastic cover and the bolts are right there. You might be able to simply use vise grips and unscrew enough to push the head back out and transfer the vise unto the bolt head and finish the job.

 

[Valpo Jeep]

Once you have broken off the extractor then its a real PITA. You might be able to use a punch to help dislodge the broken tip. If you can get the tip out then you can center punch the bolt and drill the head out then extract once the hinger is off. There should be enough of the bolt body to grab with vise grips.

You can try like @Steph1 suggested and remove the inner molding and grab it from the threads and back it out. I suspect they put some sort of locktite on it to help the holding power. Not sure you can get a bigger bolt with a larger T-head to go back in that location though. Often manufactures build without the idea of how to maintain something.

Back when I was at the steel mills we got a new machine and and during the walk through looking at one of the hydraulic cylinders hanging off the roof 20 feet in the air one of our guys said HOW THE EFF ARE WE SUPPOSED TO CHANGE THAT. Builder said WE JUST BUILD IT, WE DONT FIX IT.

 

[cafecito820]

We just had that happen on my brother’s jeep a few weeks ago.

Just open your tailgate remove the inner tailgate molding/plastic cover and the bolts are right there. You might be able to simply use vise grips and unscrew enough to push the head back out and transfer the vise unto the bolt head and finish the job.

Dude thank you! I had installed a tailgate table a long time ago, I guess it just never occurred to me that those bolts where the hinge bolts.
I think my last resort will be some strong vice grips from the back side, and a sacrifice to Odin.

 

[GATORB8]

Dude thank you! I had installed a tailgate table a long time ago, I guess it just never occurred to me that those bolts where the hinge bolts.
I think my last resort will be some strong vice grips from the back side, and a sacrifice to Odin.

Since you need to thread it through the tailgate, it may be better to flathead notch it. Just in case the vice grips fuck up the threads you have to get out.

 

[cafecito820]

Since you need to thread it through the tailgate, it may be better to flathead notch it. Just in case the vice grips fuck up the threads you have to get out.

Excellent point. You probably saved me quite a few F-bombs with that.

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