Broke/Sheared roof rack bracket screws, HELP!

OK, first off I am very embarrassed by my mistake I am posting about...

I just got the OEM roof racks for our 06 double cab for my DH for his birthday - Big surprise for him, and was started installing them myself while he was at work yesterday. This install was supposed to be a "no problem" deal..I read the instructions thoroughly, familiarized myself with the components, got my tools ready and started.

Well, DH got a new (brealking, not click) torque wrench (ft-lb) which is the one I grabbed when getting tools ready and I misread the torque units in the instructions (lbf-in), so you see what happened, and I did it twice. I am usually very good at converting, and I actually questioned the value in my mind, but still misread...I think in my excitement of the surprise for DH.

OK, so now I have a roof with two broken/sheared screws...with the loctite in the roof of my truck. I tried one of those screw extractor kit deals, but I think they are ment to work with softer metal like zinc, so that was a no go.

does anyone know where I can go to get these screws removed without completely messing up the threads in the roof? I am thinking a local autobody shop....ugg, I am just so embarassed by this and I hope that I can still surprise DH with the racks installed before this weekend.

Thanks in advance!
Lori

 

What is DH?

 

I'm guessing dear hubby.


Best getting it fixed, as Chris said take it to a shop, props for a cool gift for DH.

edit: oops Chris beat me to it lol

 

his gender says male so it cant be for his husband......oh wait its 2009 i guess it could be.

 

Maybe she didn't want to get harassed for being a woman?

 

sorry, I am a female (do women get harassed on this board?) not male...didn't realize that I was listed as a male....i'ts fixed now...sorry for confusion...and yes, DH is dear hubby- I guess I am on too many boards...

Thanks for the help....

I like to surprise DH with accessories on his truck, even though I am the one who drives it mainly...last time it was step rails, I installed those too. I need an idea for the next surprise...these forums are great for inspiration.

 

I've not seen any women harassed on this board, just thought it might be a concern.

I actually had a similar problem very recently when removing the ring gear from my diff carrier. I tried drilling the hole and using a bolt/screw extractor, but it broke off. Those kits are designed for high torque apps especially when locktite has been applied.

I was able to remove the ring gear once the bolt head came off which revealed enough of the shaft that I was able to remove the bolt with a huge wrench. I don't think that will be a viable solution for your roof rack problem though.

 

I tease my wife that on her message boards, DH more often than not means "Deadbeat Husband".

 

Ha Ha


I would also suggest taking it to a shop.

 

Supercharger?

 

i've broken off several bolts on my days of wrenching... usually i find it easiest for me to just weld a nut back on the top of the broken bolt if there's sufficient room and then remove. i've used this method several times, even once on a broken bolt through the head of a 22RE motor.. always works like a charm. only problem i see using this method for your delima is that there is alot of plastic around to melt with the heat created... good luck and i would advise to just take it to a shop you trust!

 

Thanks for all the advice...(and the post that made me feel slightly less embarrassed....I'm thankful I know the difference between the oil and tranny plug...AND that pink fluids are not all equal.)

So I got over to a shop and they FINALLY got me in and were able to remove the fasteners. They were wary of welding a stud, so the ended up drilling them out then using an easyout.

I can find M6 x 15 screws on McMastercarr, but I am having dificulty finding a good replacement for the Mastic Washers that I destroyed.

Does anyone have a source or alternate solution for the mastic washers?

Thanks!

 

You will be suprised how well these work..............I have pulled many screws and bolts w/this..........good luck!



http://www.4grabit.com/Default.asp?bhcp=1

 

I would say no. for a short answer.