I'm replacing the front doors on my 1990 XJ. The driver door had already been removed once to replace a hinge weld so those bolts came out with no issue. The passenger side, however, is apparently untouched as the bolts seem to have been tightened to 12,000,000 foot pounds. They won't budge. I PB'd the crap out of them but still nothing moves (much).
I understand at the factory the threads are treated with a hardening compound upon assembly? Will a torch heat up the bolts enough to soften the compound so the bolts can be removed? I'm afraid I'll strip these things if I go any further.

 

I use a handheld propane torch on medium and stick the tip of the blue flame right in the torx hole and heatit up for a minute or 2. That usually softens the factory loctite.

 

My Torx were rusted fast on my hinges. No amount of heat was able to budge them, and I almost busted my torx bit. I had to grind the heads off with a Dremel. Not fun! I got replacement hex-bolt stainless steel to go in place of them when I put my door back on. Curse you, Chrysler! I hate torx with a passion.

 

Cool. I will try some heat then. If that doesn't work I guess I'll brush the dust off the ol' Dremel.

 

I made this

 

Get a 6 pack ready, and be prepared to swear like a sailor.

 

Well, I'm a Marine so that won't be a problem lol

 

Ha!! I wish I'd seen that before I bought a 10" breaker bar that barely fits in there.
Oh well. Can't have too many tools, right?