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

[Justin U]

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

 

[Tech By Trade]

Ouch, that totaly sucks...Feel for you, I hate when that happens. At least if there were a bit sticking out you could get on it with a welder. Myself, I would start drilling, and hope I could get away with a tap, worst case a helicoil. I have never had much luck with easy outs when things are rusted up like that. Perhaps someone else has a better procedure.

 

[410Fortune]

Ouch!!!
A torch could have broken the rust and enabled you to get those out
Now you are in a rough spot. An angle drill might be able to start cutting into those, you are going to need some good drill bits and alot of patience. You gotta drill those out, drill the center of each bolt start small work larger until you reach the threads, then you can pick the remaining bits out of the holes, chase the threads and start new.

You could also weld some studs on there to hold the bushing brackets? or just weld the brackets onto the frame? Carefully.......

That is not a good place for broken bolts
Jacking the truck up and taking the tires off might gain you some clearance for drilling.
Is the blue stuff lock tite? Who put that on there?
I feel for you on this one, I have spent weeks and weeks and $$$$$ on drill bits fighting one bolt before...not fun

 

[MaxOffRd]

I just had this happen to me but I’ve only just started and have only broken 1 bolt. I am at a loss as far as what to do now. Not much room to drill, I even torched the bolt first as I assumed there was blue locktite, and there is, likely on all of them. Very frustrating.