Jeep Hardtop - Stipped the screws, won't come off!!?

Question

I have tried everything that I can think of to get the screws out and I am making zero progress! It's only 2 of the screws that are stuck. I've tried drilling them out, I've tried an impactor drive, I've tried a few ideas that I've found online and nothing is working. Does anyone have any tips? They are the screws with the star heads on them and of course they are the two in the most difficult places to get to so I can't even find a nut splitter that will fit in there at all. Any help would be greatly appreciated!

I did try an easy out but it's just doing anything. I tried vice grips but even the small ones won't fit. There's just no room to work at all.

Answer 1

By "stripped", do you mean the hole in the top of the bolt where the Torx drive goes in? i.e., the bolt and nut threads are intact, but the notches that the star drive engage are worn round?

If yes, try a hex wrench. You might be able to tap one in with a hammer that will grab the bolt and let you twist. You can also try going up one Torx size and again tap it in with a hammer and see if it will grab.

The next suggestion is more brutal. Try to reach the bolt heads with a hack saw blade or a mini die grinder (i.e., in a Dremmel tool). Cut a notch into the top of the bolt so that you can put a flat screwdriver in the notch and turn the bolt. Work very gently and take your time so you don't slip and gouge the fiberglass.

If the nut/bolt threads are stripped but the Torx bit can still seat properly and turn the screw head, use a flat screwdriver to pry upward on the bolt head as you rotate it with the Torx driver. You might need to go underneath to where the bolt protrudes downward, and apply pressure upward on the end of the bolt using a small clamp or pliers if you can get them in there.

I hope this helps. Post back if you're still stuck, I'll wrack my brain for more solutions.

Answer 2

Jeep Hardtop Hardware

Answer 3

Oh man I feel your pain. Those are called Torx bolts by they way and they were invented by the Devil himself. If I could find the guy at Chrysler responsible for putting those on Jeeps I'd punch him square in the nose.

I'm afraid I can't offer much advice, other then taking it to a mom and pop type auto repair place and paying them to take it out for you (this is what I've had to do in the past).

I DO have this one piece of advice for you, once you have them all out, take an intact one to the hardware store and get some hex-head bolts the same size so you won't have this problem in the future.

Good Luck!

Answer 4

Needle nosed vice grip might work. or an easyout for the drill