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: