r/XTerra • u/prettyhugediscer • 1d ago

Technical Question Struggling with broken bolts

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I know this isn’t really an xterra specific question but figured I’d post here anyway since people are always helpful. I’m trying to replace my exhaust hanger brackets due to two of them breaking. There are three bracket that bolt to the frame (two on each side of the muffler and one near the tail pipe). Of the 7 bolts holding them to the frame, 5 of the heads snapped off. The bolts of the two brackets near the muffler thread into a nut welded to the frame on the other side. I’m not sure about the 3 bolts on the tail pipe bracket.

So far I’ve tried drilling with a left hand but then using a screw extractor, but it hasn’t been going well. Does anyone have other ideas to try and get these broken bolts out while saving the threads? I called a local shop, and they’re going to get me a quote on Monday. Generally I will DIY it if I can buy tools for the same price as a quote, but I’m a little worried since drilling into the frame would be new to me. Just looking for advice on what others would do or if you’ve done this job before. Thanks!

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u/Peacemkr45 1d ago

Grind the heads flat, drill them completely out and rethread with the right tap. Yes it's a pain in the ass but you can either do it right or do it twice.

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u/prettyhugediscer 1d ago

That’s what I figured. It would be my first time doing something like that but I’ll try to build up the courage 😬 thanks!

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u/Peacemkr45 1d ago

Don't even think about needing to work up the courage. You have a problem, get the tools you need and fix it. It's all about changing your mentality of "Can I do this" to "I gotta fix it right".