Need Advice: Broken strut mount stud...
 

I was installing my new Hotchkis front suspension crossmember and have twisted-off one of these studs that the crossmember bolts up to.

Before you say it... I was using a torque wrench set at 14ft/lb. :)

In any case, how do you figure I can fix this? Not sure what kind of shop to take this one to. The stud broke but not before twisting out of its seat. There's no way to get another bolt into there from underneath so it's going to involve cutting/welding (I would guess).

Other than this, the crossmember bar is nice. Firm even though I'm missing one connection point.

Any help is appreciated!

http://i.imgur.com/fttho.jpg

Rough directions/suggestion:

Remove the brace. Get a high quality drill bit that is about 1/2 the size of the original shank. Drill a hole with the drill bit in the center of the broken bolt. Get an easyout bit to fit the drill bit. Use the easyout to remove.

http://en.wikipedia.org/wiki/Screw_extractor

If in doubt, pay a professional for help. Good luck.

Every strut mount I've seen has these pushed in. I wouldn't trust anything but a replacement. Sorry man.

Could you take some more pics of the bar though?

Yeah, you can tell these were pushed-in, as well. I guess the good thing is that I pulled out most of the backing plate when this happened. I'll take it to the Scion shop to see what they suggest.

Thanks for the help, guys!

Might be time for some whiteline com-c top hats.

Yeah you're going to have to take, it apart push that one out and push a new one back in an easy out kit only works if it was screwed in not pressed in.

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I didn't think about this properly when I made my earlier post. The easy out is the right answer for stuff that is screwed in, but not pressed. I vote COMCs!

After going out and looking at mine, what you sheared off was one of the strut tower brace to firewall studs, not one of the front strut bolts. Since you busted off the one that is closest to the tower and the bracket is welded to the tower, I'm not certain you can even get that broken one out as it feels like the flat part on the underside is possibly captured by the welded bracket?? Maybe a small mirror and flashlight will give you a better look at it.

Isn't that just the top mount? I imagine it probably cost more in labor to replace than the actual part, so DIY time:thumbup:

Oh yeah the strut has to come off the spring removed the bolt pressed out then that whole process in reverse to put it back together. Going to take an afternoon so cue the music crack a beer and get to work.

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No worries. You will be the first of many of the twins to do this. These studs only require just past hand tight. If you are using a torque wrench(which I don't reccomend) - set it lower than 12lb ft. Really you can put these on with a 1/4" or 3/8 ratchet just past snug.

This was/is a common occurence forever now with the Impreza guys/gals.

After a second look, I agree with Mr. Goat.

Thanks for the thoughts/suggestions, guys. I'll need to take a better look at what I'm up against and plan accordingly.

Happend to me today also, i broke off a stud but not to the crossmember, but for the strut itself. I will have to remove the whole strut and knock that stud out and insert a new one.
As for now i'm driving around carfully with just 2 out of 3 bolts attached to the strut :eyebulge:

And of course you cannot buy the stud alone @TOYOTA. You have to buy the whole topmount:mad0260:

Yeah plenty of Impreza owners have snapped those studs. Unless you have a low-torque torque wrench, usually something that low isn't very accurate on one which goes up to like 150 lb-ft.

I'd probably buy the whole topmount, I gotta say. I don't like crashing cars much due to changing suspension geometry.

Yeah and these shocks are all subaru it seems. weak ass studs. And a new topmount one costs about 155$ over here in Sweden.
My old mitsubishi evo top studs are almost twice the size :(

Anyways there's plenty of room underneath so i can probably replace the stud without even removing the whole shock assembly. Anyone got a tip for getting the old broken stud out? :D I tried hammering away but it did not move an inch....

God damn that stud is hard to get out!
Looks like i'll have to remove the whole top mount and get it pressed out instead. :(

Is ur problem solved？I had the same problem today..

It's already been said, but people keep mentioning the top mount so it's worth repeating...

That's not one of the top mount studs, it's one of the studs for the factory strut brace. Doesn't matter what you do with the top mount, that stud will still be missing.

If you can't get a new one in by press fit, find a shop that can weld in a new stud for you. Shouldn't cost too much.

Since it is the brace stud, I think I do not have to get a new one right? It may not be a serious issue.

I would want to fix it if it were my car, but I seriously doubt you'll see anything happen as a result of leaving it as is.

hate to grave dig but this happened to me today while installing my grimmspeed strut bar... can anyone advise?

@cobrabyte

what did you finally end up doing to fix this?

is OP still an active member?

has anyone tried this approach to see if it works?

broke one of the strut brace bolts (circled in red, not my photo) :slap:- thats what i get for being a noob

Let me know if anyone solutioned around it, otherwise maybe just weld another is the solution.

Did you use a torque wrench when you installed it? I believe it's supposed to be 12 ft/lbs only.

well, looks like im a member of this club as well. I managed to break the same bolt as just about everyone else in this thread (second one on oem strut brace where it connects to teh firewall).

Been physically ill since it happened. I am at a loss as to how you can fix this as the backing to the bolt appears to be welded to the firewall.

it seems like every thread ive found with this issue never has a resolution...

My question is who HAS fixed tihs and what did you do?

If you havent fixed how has the remaining bolt held up? What kind of driving have you been doing?

Ive already talked to my mechanic and he says its fixable (how is beyond my skills and resources).