Replacing windshield hinges, any ideas. -
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post #1 of 5 Old 08-28-2001, 09:33 AM Thread Starter
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Replacing windshield hinges, any ideas.

Hey there,
Anyone have any great ideas on how to get my old windshield hinges off. I tried to use a star bit and the egges just stripped off and it stripped out the bolt on the hinge a little bit. Will some star bits be stronger then others? Any ideas?


91 YJ, 4 banger, 3" Rough Country, 3" body lift, 31X10.5 BFG KO's on 15X10 bajas, K&N, restrictor removed.

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post #2 of 5 Old 08-28-2001, 01:17 PM
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Get yourself a torx bit that's guaranteed, like Craftsman. I must have run through 10 of their T45's, but I never paid for them. If you have an impact wrench, use it. Try soaking the bolts with CRC overnight. Otherwise, drill away...

It's not so much a labor of love as it is shear determination.
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post #3 of 5 Old 08-28-2001, 11:41 PM
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Drill them out if the paint is good if not mig a 9/16 nut on and turn them out. Oh yeah, mig the nut on the inside. The heat will loosen them.

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post #4 of 5 Old 09-05-2001, 09:54 PM
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I just picked up a 92 YJ about a month ago and I think the guy that owned it before me never took off the hard top. It was held down with torx bolts and I sheered off all the bits at my work trying to get those suckers off. I eventually had to take the drill to em. Hope you don't have as much trouble as I did. If you do get em loose let me know how you did it, I've got some new hinges on the way and I'm sure I'm gonna have the same problem

1992 YJ, 2.5L 4-banger, 2" Lift, 31x10.5 BFG Mud Terrain, K&N Filter, Restrictor Removed, Hi-Lift, Custom bumpers, More to come...
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post #5 of 5 Old 09-06-2001, 06:53 AM Thread Starter
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Hey Jeeper Jay and whoever is interested,

Ok well I worked on the hinges last night, I was having problems with all of the bolts with the torx bit I bought at autozone. I stripped out 3 of them, conclusion was that the bit was junk. So I got some very strong bits from Home Depot and I was able to get all free except those same 3. Issues:

Broke off a strong bit in one of the bolts. I tried to drill through it with a Cobalt Drill bit and I just could not do it. I had to call it a night after that. So I need some advice on what to do also with that bolt.

The bolts on the top part of the hinge go into a plate on the inside with threading so I bought a bolt extractor kit from Autozone (seems to be a good product) which may work for you. Basically what you do with this thing is drill into the center of the bolt with a very strong cobalt bit. Then they give you another bit which you insert into the hole and turn the other way. It is tapered so as you screw it in (counter clockswise) it will get tighter and eventually extract the bolt. I have not actually attempted this yet because of that one stubborn bolt with the bit broken off in it.

On the bottom of the hinge the bolt goes through the fire wall and has a nut on the other side. The nut is covered in some very tuff coating of some sort so I am just going to drill them out with a cobalt bit and then I got some Wing Nuts and washers from the hardware store and I will secure it with that.

So bottom line consider what is on the other side of the bolt. In the case of your hardtop bolts. I think there are threads you want to be careful of so the bolt extractor set may work for you. Please email me if you have any direct questions or any advice. I would appreciate it.

I cannot believe I am going through all this just to relocate my mirrors.


91 YJ, 4 banger, 3" Rough Country, 3" body lift, 31X10.5 BFG KO's on 15X10 bajas, K&N, restrictor removed.

o-I_ ___ _ I-o
[_ O__O _ ]
{{}}} {{{}}
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