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

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.

 

Impact screwdriver.
Break free sprayed in from underneath.
Heat if you can do it without peeling the paint.
https://www.google.com/aclk?sa=L&ai...wjR_cHC9Mj1AhW_IEQIHTluBb8Qwg96BAgBEAo&adurl=

 

spray with 50/50 mix of acetone and automatic trans fluid. Let it soak for a few days, repeating spray periodically.

 

Impact driver?

 

yup- pb blaster + impact driver.

 

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

 

I'd start with some PB blaster and a manual impact driver

TEKTON 3/8" Drive Impact Screwdriver Set (7-Piece) | 2905

https://www.amazon.com/TEKTON-2905-8-Inch-Manual-7-Piece/dp/B000NPPATS

 

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.