Broken rear swaybar bolts (1 Viewer)

[CharlieS]

Hi All,

I managed to snap 3 of the 4 sway bar mounting bracket bolts when removing it to install my lift. they broke off flush or below the surface, so there is no hope of getting anything on them to ease removal.

So, the logical thing to do was to just remove the sway bar until I could find time to fix the problem. While removing the four sway bar bolts on the rear axle I managed to break two of those too. Nice.

(edit... I did use tons of PB Blaster and the bolts all moved quite a ways, but when the threads got to the section that extended up past the captive nut, they got bound up on corrosion and the torque from me wrenching snapped them off. The good news is that they were the only fasteners damaged all weekend!)

I assume that I am going to have to drill and tap, yay. Worst comes to worst I'll cut them out and weld in some captive nuts. Still a pain in the neck job any way I cut it, and I won't have time to do it for a couple of weeks.

I have two questions:

1) anyone have any other ideas for getting the bolts out of the holes? Other than drill, pick, tap or cut out and weld in new nuts?

2) is there any danger in running without a rear swaybar? I assume I've added some oversteer by removing it, but I am not aware of any other issues/dangers. Am I wrong?

Thanks everybody.

Charlie

 

[Gumby]

You can weld nuts to the broken off part. Sometimes that works. The heat from the welding helps. If you broke them off when the corrosion wedged, they might spin out the back side when you drill them.

 

[CharlieS]

I never considered that. How sweet would that be if they just spun back out (or "in" in this case).

Charlie

 

[Heffenoche]

I snapped one bolt of during my lift install and left it disconnected on one side. I drove the truck like this w/ OEM bushing for a few miles. Then fixed the swaybay. I could tell a difference with the rear swaybar dissconnected but it was not much worse than when it was connected. After putting the OME caster bushing in it road even better.

 

[k5ryannc]

get ahold of a tool truck (mac, snap on, or matco) and get there kit for drilling out broken bolts that are flush or below the surface. it'll cost ya but you'll know it's done right instead of cutting and welding on the frame which can induce stress cracks. i has a collar that rests up against the surface so you can drill directly on center. super easy and i've never boogered up the original threads either!!

i'm a tech to pay the bills and this has saved my hide so many times!!

hope this helps

ryan!

 

[CharlieS]

Thanks Ryan, I'll swing by the local snap on truck guy and ask about them (I know where he grabs lunch every day). Are they called drill centering guides or something like that?

Charlie

 

[k5ryannc]

http://buy1.snapon.com/catalog/item.asp?item_ID=158&group_ID=1254

i know it's pricey but if you take cash you can usually bargin about 10 percent off. it's so worth it. use a bunch of cutting oil or wd40 if that's all you got.
and take your time and don't rush it and they'll last a lifetime!!!

happy drilling and tapping!!!!

ryan