Rusty/Seized/Old etc. issues when working on 1st Gens

Been removing bits and pieces from my '02 and would like to hear others' horror stories or how-tos on removing hard to reach nuts bolts studs and the like. Will post some of my exploits tomorrow after I get some sleep, basically just wanted to start a thread to see how everyone deals with the perils of having an older truck that, although rusty, they still really like working on and improving with pricey parts!

 

Knowing and planning the things are going to break and need to be cut apart

Kroil is your friend

Torch

cut off wheels

Having a bolt bin full of JIS bolts is another good idea.

Thread replacement kits for M6x1.00 M8x1.25 M10x1.25

$13 M12x1.25 mm Self-Locking Nylon Insert Hex Lock Nuts, Pack of 6

M12x1.25

Taps and dies in those sizes.

Weld nuts in those sizes as well

Most important is lots of patience being able to stay cool when things break

Living in the Liquid Brine Belt

 

Solid 50% of bolts on my truck will probably snap if i tried to removed. Alot of em already have been...

 

Oh boy very relevant. Check out this o2 sensor. Discovered this today while trying to change it out. No idea where to go from here. So far everything else I've handled with acetone+atf, vice grips, and a sawzall.

 

Been there all to often !!

If your lucky you can get the studs out and replace them

Living in Pa I keep the oxygen Sensor bungs on hand trying to drill out studs and replace takes way to much time.

I can cut the old one off and weld a new bung in faster ..

Then if I want to frustrate myself try and fix it later for fun most just pitched in the scrap

 

Yeah that acetone/atf has done me well on a lot of stuff but in some cases shit is just too damn stubborn. The harder something is to reach the less options one has for attacking it.

 

Nuts on mine fell off...