Photos HELP! Front Sway Bar Bushing Bolt broke :(

[MaxOffRd]

I am so irritated at whoever decided that blue locktite needed to be on these bolts, but nonetheless here we are. I have only just started this job of replacing the sway bar bushings (not the links). The first bolt fought with every turn so I figured locktite was involved, I torched it and it moved and then the heat wore off and SNAP.

This is on the front passenger side and it broke off inside the frame, it was damn near impossible to get even a ratchet in there, so I’m lost as far as how to get this out with drilling. If anyone has suggestions or ideas I would greatly appreciate them.

 

[Bazz270]

Remove the swaybar bushing bracket ,then use angled drill plus bolt extractor or reverse flute drill bit or both

Just to be clear , the sway bar rods both needs to be disconnected before

As far as i can see from the picture ,the bracket hole was misaligned before previous assembly causing the bolt threads to seize inside the frame welded nut.most common mistake on this job is to work without the sway bar fully disconnected from the control arms

 

[MaxOffRd]

Remove the swaybar bushing bracket ,then use angled drill plus bolt extractor or reverse flute drill bit or both

Just to be clear , the sway bar rods both needs to be disconnected before

As far as i can see from the picture ,the bracket hole was misaligned before previous assembly causing the bolt threads to seize inside the frame welded nut.most common mistake on this job is to work without the sway bar fully disconnected from the control arms

I did undo the links, and it was on properly the picture isn’t that great. But I was loosening both bolts and then snapped the one which is why the bracket looks droopy and off kilter. Blue thread locker was my problem here I believe. I will definitely try to get it out with the angle drill, any recommendations as to which ones?

 

[Bazz270]

Makita 12v angled drill is the most compact one

 

[MaxOffRd]

Update:

I was able to heat and remove all 3 other bolts without incident. Started to drill out the broken stud, got about 1/2” approx deep, and tried to get the extractor in but couldn’t seem to get enough room to tap the bit into the stud. I did manage to get it in eventually and got some vice grips on the extractor bit, but stud wouldn’t budge, and started to spin inside the hole I drilled.

Not sure where to go from here. I may try to drill out completely and re tap the hole, that’s the only other option I see now.

 

[Bazz270]

Update:

I was able to heat and remove all 3 other bolts without incident. Started to drill out the broken stud, got about 1/2” approx deep, and tried to get the extractor in but couldn’t seem to get enough room to tap the bit into the stud. I did manage to get it in eventually and got some vice grips on the extractor bit, but stud wouldn’t budge, and started to spin inside the hole I drilled.

Not sure where to go from here. I may try to drill out completely and re tap the hole, that’s the only other option I see now.

What about reverse drill bits?

 

[MaxOffRd]

What about reverse drill bits?

I did already drill all the way through to a 7/32 sized hole. I would have liked to try the reverse bits but I couldn’t find any at Lowe’s when I was there and I’m not sure if they make them with the 1/4” impact shank.

 

[wollimann]

I may try to drill out completely and re tap the hole

Maybe its possible to build a smaller internal thread into the rest of the broken bolt.
Maybe not fully through, only to scew in a smaller bolt in to loosen the broken bold end.
You do not want to disturb the original thread or rip of the inner nut.
So maybe some additional heat or WD40 would loosen the sticking bolt.
But it looks like there is less space for big activitys.

Front — 2004 Ford Explorer 4WD V6-4.0L VIN E Service Manual | Operation CHARM

Detailed repair manual for the 2004 Ford Explorer 4WD V6-4.0L VIN E.

charm.li

same thing here

Sway bar bushing bolts broke how to remove? (Not linkage bolts)

Hi i was trying to replace the large bushings 3 of the bolts snapped. Now I'm at a loss on how to remove them. I tried getting a drill up in there but don't have the room for the front ones and the back one i can only come in on an odd angle. Driver Side Pass. Side

www.explorerforum.com

 

[MaxOffRd]

I have exhausted the efforts of my abilities and will admit defeat to this damn bolt. I’ll be taking it to my trusted mechanic and see if he can get it out and retap it.

 

[TechGuru]

I would weld a nut to it.

 

[MaxOffRd]

Took it to my mechanic and he welded the bracket back on with tack welds. Shouldn’t go anywhere and will be faster to take out than the bolts lol. Said it probably would’ve costed more to get it out than it’s worth.