Help...I'm stuck!

I'm installing the EZ 43601 tailgate support. It was relatively easy and I was 2 steps from finishing the install...but when I got to removing the bolt (40 torx) from the tailgate, I managed to stripped the bolt (40 torx is now zero torx!). I know I will have to get a new bolt but I need suggestions on how to remove it first. I'm stuck. Thanks.

 

Easy out. It's like a reverse drill bit. Any auto parts store should have one. They are also called bolt extractors. I've used them a few times and the work well.

 

1. Get this kit and follow instructions.
http://www.thisnext.com/topic-allen-wrech-screw-driver


2. Dremel a big slit across the top, and use a big flat head screw driver.

 

Thanks guys...here's a photo of mistake...

 

vice grips if you can grab it

 

Couple of choices.
1. EZ out. You can buy one from Lowes or Home Depot
2. Drill out the head about 2/3 deep. Hammer in a larger hex driver into the head and reform the head to a hex... This will be very HARD and may not work depending on how soft/hard the bolt that is stripped out is. Turn the bolt carefully and back out the bolt.
3. (last option) Drill out the head and go down thru the bolt with a drill bit that is one size smaller than the bolt that is stripped... be very careful... the next step will be to run a tap down and clean out the thread. This isn't easy but I've done it on my wife's Sequioa and it worked.

Edited: changed the order...

 

weld a nut on it and use a wrench or socket

 

I believe the part is labeled for 2005-2008 Tacos only... Those torx screws appear to be tack welded in '09+ trucks.

Open the tailgate liner and have a look at the screw from the inside. Maybe you can drill out the screws completely and use conventional nuts and screws to hold the new bracket in.

 

question is, why did you keep going when it started to round out?

 

if you dont want to buy bolt extractors or dremmel a slit across it for a flat head, just grab it HARD with a big ass pair of vise grips and slowly turn it out

 

X2. Just tack it a few times, don't WELD it or you'll eff other stuff up from heating it up too much.
I have had pretty much zero luck with those damn EZ Out POS bits....

Good luck whatever you do!
The dremel trick would be my 2nd choice. Do you have an impact hammer?

 

It was stupid on my part...I'm the type that don't easily give up. Bottom line, I screwed up. I went to Home Depot and got a set of one of those EZ outs. I'll drill it, tap it in, and see if it works. If that doesn't work, I'll cut a slit with my dremel tool and use a large screwdriver. If that still doesn't work...man, I'll start drilling (carefully) until I get the bolt out. I'm just glad this forum exist...thanks guys!

 

I would think if you can remove the other bolt, just drill out the head (it's a taper-head) then once you remove the part that's bolted on, grab the remains of the bolt with a simple Vice-grip.

RZ Rob

 

Update: The Black and Decker EZ out did not work...it broke. I tried drilling...this will take some time. I managed to cut a nice slit for a large size screw driver. I'll try that when I visit my brother. He's got a small torch. I plan on using a large screwdriver after heating it up. (CraigTRD..no, I don't have an impact hammer. KenLyns...you may be right...it could well be tack welded.) Thanks guys!

 

HAHA O SHITTTT that sucks. Definitely keep us posted on what you do next. I've heard those ez down tailgate dampners can be real tricky. I'd like to see if you manage to get it to work.
Good luck

 

Final update: Got the tailgate dampener finally installed. My brother (a Harley guy who's got every tool in the world) first drilled it. He then used his blow torch to heat it up really good, hammered another ez out in the hole and voila!...damn tapered bolt came right out! It was easy to finish after that. NOTE: Much like every one else who installed this dampener, we discovered that the tailgate cable is now getting in the way of the dampener when closing the tailgate. You can still close the tailgate but as my brother said...it was annoying having to move the cable out of the way every time you close the tailgate. Next step would be to replace the cable with a thinner more flexible cable that will not bind with the dampener. Thanks guys!

 

I remember from a post on here, someone used a zip tie to hold the cable back to prevent it from getting in the way of the cable. He said it worked out well for him.