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Getting star drive bolts out without stripped heads

Discussion in 'Wrangler TJ (1996-2006)' started by Joelmooch, Jul 14, 2019.

  1. Jul 14, 2019 at 6:54 PM
    #1
    Joelmooch

    Joelmooch [OP] New Member

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    Vehicle:
    2000 Wrangler
    Is there a trick to getting the star drive bolts out without stripped heads. Having trouble with the tail gate hinge on wife's 2000 Wrangler.
     
  2. Jul 14, 2019 at 7:11 PM
    #2
    aggrex

    aggrex Well-Known Member

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    DE
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    Tuffy>AEV>TTO>JW>STech>EVOcage>MagnaFlow>SpiderTrax>RockHard>TF>SpringTail>67design>Bolt>GPCA>Curt>
    Rust/corrosion could complicate removal. Use penetrating oil, quality star bit, mid-length breaker bar keeping steady pressure on the fastener. Consider new fasteners if damaged or corroded.
     
    JKBob 25 and Bob like this.
  3. Jul 15, 2019 at 4:09 AM
    #3
    Joelmooch

    Joelmooch [OP] New Member

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    Thanks. Tried with penetrating oil but not the breaker bar. I am going to have it painted and think we are going to replace the hardware with brushed stainless ,so I am going to have to go over the whole Jeep and remove all the bolts and put them back in with never seize .
     
  4. Jul 15, 2019 at 3:06 PM
    #4
    Jim Beam

    Jim Beam Well-Known Member

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    Fuel Injection, Dana 44s, T18, 4.10s w/lockers
    I believe you are talking about torx Head bolts. Removing one with a stripped head can be a lot of fun. A vise grip might get a grip on it, otherwise you can drill them out. A left handed drill will sometimes work as it will grab hold of the bolt and back it out. An easy out can help but only if there is little resistance for getting it out. If you could drill it out on center to the tap drill diameter them just pick out whats left.
     
    JKBob 25 likes this.
  5. Jul 16, 2019 at 6:26 PM
    #5
    steelhd

    steelhd Member

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    Heat and impact. I use a propane or MAP gas torch and a 3/8" impact gun. Put the torch's blue flame cone right in the torx slot, back it out, repeat many times until the bolt is hotter than hell. As the bolt cools hit it with the impact. May take a couple of evolutions and the process will ever so slightly slightly discolor the paint but not noticeably (mine is silver, darker colors should be better) if done correctly.
     
  6. Aug 14, 2019 at 3:31 PM
    #6
    Jackryan12

    Jackryan12 Member

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    Big channel locks
     
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