Hi!
I'm trying to replace worn out bushings for the rear track bar on my '95 Grand Cherokee. Geez, was a torx type bolt really the best choice for a heavy bolt completely exposed to road salt, etc.?
Anyway, I'm about out of ideas. I've only attempted to remove the passenger side bolt (attached to the frame rails, not the axle). I haven't (completely) stripped the torx bolt head, but enough that it will never come loose through conventional means. I have used liquid wrench, spent considerable time cleaning the threads of the bolt, various types of mechanical persuasion. I'm not comfortable with using any method of heating the bolt due to the the proximity of the gas tank and brake lines.
I gave up after trying to weld a torx bit directly to the bolt head, but the bit's steel is just too hardened to get any penetration with my little mig.
What would the experts do in such a situation? Torch off the bolt on the nut side and start anew? I wouldn't do this myself, for the reason mentioned above (not to mention, there is a steel shell around the bolt on the axle side, making this a very difficult task for someone using jack stands).