Trying to remove the rear fender struts on '03 Fatboy and several of the torx bolts are seized tight. They feel like they're on the verge of stripping. Tried PB Blaster but several bolts still won't budge. And tips other than drilling out which I'd like to avoid?

 

Here are a few tips, in addition to the penetrating oil and making sure you're using the proper size torx bit...


1) Try heat... I use a heat gun (or your wife's hair dryer will work) rather than a torch on most bolts that I heat up... always be careful using heat around painted parts

2) Then try a manual impact driver:

https://www.sears.com/craftsman-impa...190612143715:s

3) If these don't work graduate to a battery operated impact driver:


4) Of course on bigger bolts, you can then graduate to a pneumatic impact wrench. I only use a breaker bar on nuts/bolts holding something that could be damaged from the vibration of the impact drivers.

I have these tools and have used them successfully on "stubborn" bolts. If used in the listed order (heat, manual impact, battery impact, then pneumatic impact - breaker bar when applicable) I can get most nuts/bolts out... if they strip using these steps, at least I know I gave it a solid attempt to save the fastener....

Good luck...

 

Definitely good advice from hattitude.
Heat those stuck bolts up first, a soldering iron held to the head of the bolt works too.
I had one on each side that wouldn't budge til i heated them, that thread locker the factory uses is like glue LOL.
Good luck.

 

They probably have Red Loctite, so heat them up to loosen it.

 

I have a set like this that I use to get stuck bolts out. I'm not sure what size the Fender Strut bolt is though... These work great.... You will probably need to replace the bolt since these tend to cut into the head.

https://www.harborfreight.com/9-pc-3...set-67894.html


MIke
NY

 

I'll reiterate what was said first in post #2, use the correct TORX bit. Many a T27 has been stripped by a T25 bit. Get good quality hardness bits. Avoid the "K-Mart" special type. Patience is often needed.

 

Heat will help. You don't need a hammer type impact, just a hammer. Slip the torz socket into the bolt and tap right straight down with a ball peen. Try to remove. No luck repeat.

 

This works just Ok with a regular hex head bolt but with a button head like the Allen/Torx there isn't much to grip. Those tools also are not particularly effective in a hardware grade bolt, too soft to hold a grip and likely to snap anyways. Reference the comment about heat and red loctite, I would check the real service manual and look for the installation procedures and see if HD call for any particular grade of thread locker. If red or equivalent, heat WILL be required. Loctite says in it's discussion that not using heat will likely result in the bolt breaking.

 

Heat with the manual impact driver did the trick. A new tool for the box. Thanks for the tips! Always appreciated!

 

If loctite is on them, penatrant has no effect. Lot of places, big torix fittings, oil, chrome or powder coat, I use a air impact. Bolt is trash but they come out.

Heat concerns me and a hand impact won't work on a springy area. If you cannot afford at least a heavy electrical impact, you really ought to farm Harley work out.