'78 FJ40 spare carrier bolt replacement

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Apr 30, 2019
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Albuquerque, New Mexico
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The bolts (not studs) on my carrier were so stripped and worn that I was worried about losing my spare. The bolts I had were just #5 bolts tack welded to the carrier. There's no room to get an angle grinder in there so I used a Dremel and some abrasive cutoff wheels. I also had to use a cold chisel to get the top passenger-side bolt out and make room for the new stud. Then I had to take a step-drill to get the actual studs to seat. The metal on the carrier is not thick/strong enough to get the studs to swage in. I was able to get the old welds off enough to get the new studs in and weld them in place. Worked like a charm. When I can get my antique phone to get the pics onto my laptop, I'll share the pics.
 
Joined
Apr 30, 2019
Messages
55
Location
Albuquerque, New Mexico
Visit site
The bolts (not studs) on my carrier were so stripped and worn that I was worried about losing my spare. The bolts I had were just #5 bolts tack welded to the carrier. There's no room to get an angle grinder in there so I used a Dremel and some abrasive cutoff wheels. I also had to use a cold chisel to get the top passenger-side bolt out and make room for the new stud. Then I had to take a step-drill to get the actual studs to seat. The metal on the carrier is not thick/strong enough to get the studs to swage in. I was able to get the old welds off enough to get the new studs in and weld them in place. Worked like a charm. When I can get my antique phone to get the pics onto my laptop, I'll share the pics.
 
Joined
Apr 30, 2019
Messages
55
Location
Albuquerque, New Mexico
Visit site
Upper driver side. A buddy of mine has a welder. I’ll just ask him to do what he can. I’m not too concerned with the final look.
That's the middle-difficulty. Get in there with a Dremel and an abrasive cut off wheel. Take out the welds around the bolt head and tap it with a hammer. It'll come right out. You'll have to use a step drill and/or die grinder to clean up the welds in back and get the hole big enough to take an actual stud and swage it in. Once that's done, it's a minute of welding to get the new one set in.
 

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