Worst stuck bolts I’ve ever come across X2

[Captain Spaulding]

Installing rear air bags on my 2014 truck. Need to remove the rear jounce bumpers and it has been a nightmare. Above the axle, inside the frame rails with brake lines, exhaust, gas tank and wiring in the way. It would be nearly impossible to get anything in there other than a standard box or open end wrench even without the “utility” lines. Can’t see the nut and the head of the bolt is a large steel pipe encased in plastic that doesn’t turn because of a notch in the frame.

Got a box end on one and was able to get a few very difficult turns on it before it seized. Not enough leverage to break it off. The other one won’t turn at all. Not enough clearance to get an air chisel to stay on. No chance of a recip saw or angle grinder. Cut off tool will fit, but the blade won’t reach with the angle I can access it. My torch and plasma cutter are non-starters with everything in the area. I broke two nut-splitters which don’t work too well because they are flange nuts.

Cut one of the bumpers to get access to try to drill, but the axle forces the drill to engage at an angle, and since there are multiple pieces the bit keeps running and grabbing before breaking.

I’m going to try an oscillating tool tomorrow when I can get blades for it. I’m hopeful, but not incredibly optimistic.

Honestly would have been easier to pull the bed.

 

[Walkers]

Hmm, my bags utilized the ounce stop bracket. Mine is a 2500 though, maybe that is the difference.
It is too bad that air tools have fallen out of favor for battery tools, because air tools had one tool in particular that used to be in every mechanics box, an air chisel. 30 seconds or less could reduce most automotive fasteners into pieces. I love mine when hey are needed.

 

[Jlarson]

Did some on a Superduty the other day, cut one side of the nut off with a die grinder w/cutoff arbor then one blip with the air hammer and the rest of the nut flies off.

 

[theoldwizard1]

Ever watch the YouTube channel Bus Grease Monkey ? He just broke the handle on a "torque multiplier" !

 

[Sumboodie]

Hmm, my bags utilized the ounce stop bracket. Mine is a 2500 though, maybe that is the difference.
It is too bad that air tools have fallen out of favor for battery tools, because air tools had one tool in particular that used to be in every mechanics box, an air chisel. 30 seconds or less could reduce most automotive fasteners into pieces. I love mine when hey are needed.

I'd imagine it varies on make.

I've had some that go in place of the bump stops, others that mount on the side of the frame over top of the leaf pack.

 

[Captain Spaulding]

Hmm, my bags utilized the ounce stop bracket. Mine is a 2500 though, maybe that is the difference.
It is too bad that air tools have fallen out of favor for battery tools, because air tools had one tool in particular that used to be in every mechanics box, an air chisel. 30 seconds or less could reduce most automotive fasteners into pieces. I love mine when hey are needed.

I have and use an air chisel regularly. I had hoped it would be the answer, but I don’t have enough leverage to keep it on the nut since I can’t quite get it at 90 degrees to the nut. It dances off, and with the nut being a flange nut I can’t use that 90 degree joint of the nut and frame to get some purchase for the chisel to stay still long enough to start working.

I will say that rattling your truck with an air chisel while you are underneath it soaked with sweat is an excellent way to get really dirty!

 

[Ign]

Installing rear air bags on my 2014 truck. Need to remove the rear jounce bumpers and it has been a nightmare. Above the axle, inside the frame rails with brake lines, exhaust, gas tank and wiring in the way. It would be nearly impossible to get anything in there other than a standard box or open end wrench even without the “utility” lines. Can’t see the nut and the head of the bolt is a large steel pipe encased in plastic that doesn’t turn because of a notch in the frame.

Got a box end on one and was able to get a few very difficult turns on it before it seized. Not enough leverage to break it off. The other one won’t turn at all. Not enough clearance to get an air chisel to stay on. No chance of a recip saw or angle grinder. Cut off tool will fit, but the blade won’t reach with the angle I can access it. My torch and plasma cutter are non-starters with everything in the area. I broke two nut-splitters which don’t work too well because they are flange nuts.

Cut one of the bumpers to get access to try to drill, but the axle forces the drill to engage at an angle, and since there are multiple pieces the bit keeps running and grabbing before breaking.

I’m going to try an oscillating tool tomorrow when I can get blades for it. I’m hopeful, but not incredibly optimistic.

Honestly would have been easier to pull the bed.

I'd be amazed if an OMT does much of anything except waste your time. They're handy for a lot of things, but cutting metal is not one of them (they do ok on nails, though)

 

[FMB4]

I'm sure that you routinely soaked said 'bolts' with a quality penetrating oil/fluid over several days before you started. If not, I'd try that.

 

[slidehammer]

I’m going to try an oscillating tool tomorrow when I can get blades for it. I’m hopeful, but not incredibly optimistic.

I'd be amazed if an OMT does much of anything except waste your time. They're handy for a lot of things, but cutting metal is not one of them (they do ok on nails, though)

The hot ticket for metal cutting with an oscillating multi-tool are Bosch carbide blades. Regular blades are terrible.

 

[Captain Spaulding]

I got one of the SOBs, finally. Unfortunately, it was the more accessible.
The oscillating tool let me get a notch started that I could turn the nut with using the air chisel.

I built a guard for the frame and used some angle to make guards for other parts I didn’t want hit. That let me cut blindly with the cutoff tool.

Got much of the nut chipped away, then began turning things with the air chisel and it finally came loose.

 

[nadogail]

I guess you just had to show that bolt a little stubbornness. Brute force and determination solve many problems.

 

[kbeefy]

If success doesn't continue, the bed is only 6-8 bolts from moving.

 

[Captain Spaulding]

If success doesn't continue, the bed is only 6-8 bolts from moving.

If it weren’t for my gooseneck hitch I’d have done that.

Finally got the second one loose about 45 minutes ago. Turned out easier than I expected, mostly because of the knowledge I got from tearing the first one apart. There are some small holes in the steel core that are probably from the molding process. I was able to get a lag screw into one and used it as a lever to spin the bumper with the air chisel. Got a few more turns which gave me room to take the wheel off and get a recip saw blade in there using a borrowed compact recip saw. When it came off I yelled out loud!

 

[kbeefy]

I just pulled the bed on my truck. First 2 bolts were easy, lulling me into a false sense of confidence. 5 of the remaining 6 had to be ground/cut/drilled out.

I understand you excitement about success!

After removing the bed I really wish I would have done it years ago to install my airbags and gooseneck hitch. Sooo easy working sitting up instead of upside down.

 

[Dogmeat]

Now...if U had a 22' long x 6' deep x 3-1/2' wide PIT like MINE....you'd be all set!!

 

[Captain Spaulding]

Now...if U had a 22' long x 6' deep x 3-1/2' wide PIT like MINE....you'd be all set!!

Got to say I’d love that