The body side torx bolts for the windshield frame had glued on nuts so
they can just be punched through. Those are the two on the body side of
the door post. A little heat can also just make them fall off the
inside.

I soak the broken bolts first in the best penetrating oil I can find.
Just a note, WD40 isn't a good penetrant.

Other than that, I take a punch and make a mark, then run an 1/8" bit
down the bolt, then one larger after. I normally soak these in oil
while drilling. I try hard to run the small bit slightly 'off' center,
I don't want it centered at all.

Then when I run a larger bit down through the bolt, it will hopefully
slightly tag the threads on one side of the bolt. This leaves a quarter
moon shaped chunk of metal in the hole that usually will just spin right
out.

Depending on how close I made the small hole, I used a 3/16" or a 1/4"
or a 5/16" bit for the 3/8" body bolts. Which ever one I think will
'just' skin the threads on the one side, but usually the 1/4" one is
right.

I have had very good luck using the above method on rust snapped bolts
and have seldom damaged the threads beyond re-use. I do use a thread
sealer like loctite on the new bolts to stop future rust.

Mike

Lovs2fly wrote:
>
> Broken bolts are two on the windshield brackets, and two on the passenger
> seat bracket and one on the tailgate to body bracket.
>
> Thanks for the help.
>
> "Mike Romain" <romainm@sympatico.ca> wrote in message
> news:43C66557.43229E08@sympatico.ca...
> > Which ones snapped?
> >
> > If you are specific, there are tricks for some of them.
> >
> > Mike
> > 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
> > 88 Cherokee 235 BFG AT's
> > Canadian Off Road Trips Photos: Non members can still view!
> > Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
> > (More Off Road album links at bottom of the view page)
> >
> > Lovs2fly wrote:
> >>
> >> OK those damm tork bolts are at it again. I'm in the mist of a rebuild of
> >> my
> >> 93 wrangler and have broken the heads off a number of tork bolts. Really
> >> not
> >> too bad out of the roughly 30 if have freed only 4 broke ott. They have
> >> broken clean to the body. Any trick or suggestions.
> >> Thanks.

 

The body side torx bolts for the windshield frame had glued on nuts so
they can just be punched through. Those are the two on the body side of
the door post. A little heat can also just make them fall off the
inside.

I soak the broken bolts first in the best penetrating oil I can find.
Just a note, WD40 isn't a good penetrant.

Other than that, I take a punch and make a mark, then run an 1/8" bit
down the bolt, then one larger after. I normally soak these in oil
while drilling. I try hard to run the small bit slightly 'off' center,
I don't want it centered at all.

Then when I run a larger bit down through the bolt, it will hopefully
slightly tag the threads on one side of the bolt. This leaves a quarter
moon shaped chunk of metal in the hole that usually will just spin right
out.

Depending on how close I made the small hole, I used a 3/16" or a 1/4"
or a 5/16" bit for the 3/8" body bolts. Which ever one I think will
'just' skin the threads on the one side, but usually the 1/4" one is
right.

I have had very good luck using the above method on rust snapped bolts
and have seldom damaged the threads beyond re-use. I do use a thread
sealer like loctite on the new bolts to stop future rust.

Mike

Lovs2fly wrote:
>
> Broken bolts are two on the windshield brackets, and two on the passenger
> seat bracket and one on the tailgate to body bracket.
>
> Thanks for the help.
>
> "Mike Romain" <romainm@sympatico.ca> wrote in message
> news:43C66557.43229E08@sympatico.ca...
> > Which ones snapped?
> >
> > If you are specific, there are tricks for some of them.
> >
> > Mike
> > 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
> > 88 Cherokee 235 BFG AT's
> > Canadian Off Road Trips Photos: Non members can still view!
> > Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
> > (More Off Road album links at bottom of the view page)
> >
> > Lovs2fly wrote:
> >>
> >> OK those damm tork bolts are at it again. I'm in the mist of a rebuild of
> >> my
> >> 93 wrangler and have broken the heads off a number of tork bolts. Really
> >> not
> >> too bad out of the roughly 30 if have freed only 4 broke ott. They have
> >> broken clean to the body. Any trick or suggestions.
> >> Thanks.

 

The body side torx bolts for the windshield frame had glued on nuts so
they can just be punched through. Those are the two on the body side of
the door post. A little heat can also just make them fall off the
inside.

I soak the broken bolts first in the best penetrating oil I can find.
Just a note, WD40 isn't a good penetrant.

Other than that, I take a punch and make a mark, then run an 1/8" bit
down the bolt, then one larger after. I normally soak these in oil
while drilling. I try hard to run the small bit slightly 'off' center,
I don't want it centered at all.

Then when I run a larger bit down through the bolt, it will hopefully
slightly tag the threads on one side of the bolt. This leaves a quarter
moon shaped chunk of metal in the hole that usually will just spin right
out.

Depending on how close I made the small hole, I used a 3/16" or a 1/4"
or a 5/16" bit for the 3/8" body bolts. Which ever one I think will
'just' skin the threads on the one side, but usually the 1/4" one is
right.

I have had very good luck using the above method on rust snapped bolts
and have seldom damaged the threads beyond re-use. I do use a thread
sealer like loctite on the new bolts to stop future rust.

Mike

Lovs2fly wrote:
>
> Broken bolts are two on the windshield brackets, and two on the passenger
> seat bracket and one on the tailgate to body bracket.
>
> Thanks for the help.
>
> "Mike Romain" <romainm@sympatico.ca> wrote in message
> news:43C66557.43229E08@sympatico.ca...
> > Which ones snapped?
> >
> > If you are specific, there are tricks for some of them.
> >
> > Mike
> > 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
> > 88 Cherokee 235 BFG AT's
> > Canadian Off Road Trips Photos: Non members can still view!
> > Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
> > (More Off Road album links at bottom of the view page)
> >
> > Lovs2fly wrote:
> >>
> >> OK those damm tork bolts are at it again. I'm in the mist of a rebuild of
> >> my
> >> 93 wrangler and have broken the heads off a number of tork bolts. Really
> >> not
> >> too bad out of the roughly 30 if have freed only 4 broke ott. They have
> >> broken clean to the body. Any trick or suggestions.
> >> Thanks.