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Changing tailgate. Can't loosen Torx screw on hinge.

Discussion in '1st Gen. Tacomas (1995-2004)' started by umpire3, Jan 23, 2022.

  1. Jan 23, 2022 at 2:18 PM
    #1
    umpire3

    umpire3 [OP] Well-Known Member

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    Bought a new tailgate shell and changed over all mechanisms from the old to the new. I can't break loose the T-40 Torx bolts on the hinge. I broke the T-40 and the bolt never broke loose. In fact it damaged the Torx splines. I had to drill it out. That's one of 4.

    Anybody have a successful way on loosening these bolts?

    2004 D-cab PreRunner with V6.
     
  2. Jan 23, 2022 at 2:23 PM
    #2
    Catcrazed

    Catcrazed Love is Dogs and Toyotas

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  3. Jan 24, 2022 at 6:17 AM
    #3
    Seagull233

    Seagull233 Well-Known Member

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    spray with 50/50 mix of acetone and automatic trans fluid. Let it soak for a few days, repeating spray periodically.
     
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  4. Jan 24, 2022 at 6:51 AM
    #4
    02hilux

    02hilux Paved roads not required

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    Impact driver?
     
  5. Jan 24, 2022 at 10:25 AM
    #5
    Andy01DblCabTacoma

    Andy01DblCabTacoma Well-Known Member

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    yup- pb blaster + impact driver.
     
  6. Jan 24, 2022 at 10:41 AM
    #6
    Bivouac

    Bivouac Well-Known Member

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    Remains to be seen I bought the tires and wheels the rest came along
    I only buy impact Torx Sockets in the larger sizes

    Soak with your favorite penetrating fluid for a day or so.

    hit with 1/2" impact if that does not break it loose bring out the torch.

    I feel sorry If you live in the liquid brine belt

    Good Luck
     
  7. Jan 24, 2022 at 11:06 AM
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    Wulf

    Wulf no brain just damage

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  8. Jan 25, 2022 at 9:42 AM
    #8
    umpire3

    umpire3 [OP] Well-Known Member

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    Can't reach the bolt from the back side of the shell. Drilled an 1/8" right above where the bolt should be. Sprayed through the hole with PB Blaster. With a heavy duty impact drill I was able to zip one of three out. The other two I had to drill out.
     

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