I pulled my sway bar off to replace the bushings and when I attempted to take off one of the bolts holding the sway bar brackets in place it broke off. Took a trip to AZ to pick up some bolt extractors and due to how cheap they were they didn't work and on top of that they ended up tearing up the threads. I ended up boring out the hole and instead using a bolt with a rethreading end. The bolt was working its way in and it was rethreading the hole but then the worst happened and I ended up busting off the welded end inside the frame. Now the bolt is stuck in that end freely wiggling around and I have no way of removing it.

Only thing I can think of is cutting or torching it off and then using a self tapping bolt??? Not sure how to approach this in order to get the sway bar reconnected. Drives nice right now but not sure it would be wise to drive on the highway which I will have to do sooner rather than later.

 

Wow!....might not be of any help but a question......

Did you soak the bolt ends etc etc with WD40 or PB blaster a couple days before you tried to take it off? sounds dumb I know.

as to the present situation, are there any GOOD 4x4 fab shops around you?

they deal with stuff like this all the time.....might be a good resource.
(yeah, I know, you want to do this yourself, I am same way)

sometimes, though a shop can help you out faster. besides you can get to know them and they can help you with any mods you might want to do later down the road.

just a thought sir and best of luck!

cpnwrench

 

X2 on the heat wrench. (assuming you don't have a cutting torch). Because it's loose it will heat up and blow away in a snap. For just that they should take pity on you and do it free! Or they could weld in a stud there?