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Old 04-20-2009, 10:04 AM   #1
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Question Pro Kit Installation problem...HELP

I attempted to install my pro kit this weekend with a friend who has worked on suspensions before. We got the fronts in no problem, same thing for the rear passenger side. When we got to the rear drivers side I ran into the frozen bolt issue. The head of the bolt just snapped right off. So now I'm stuck with a headless bolt that can't be removed, and a set of stock springs and shocks on the rear driver's side, with the pro kit components installed on the other 3 wheels.

I need some suggestions. Should I try to drill the thing out? Maybe take it to a shop for this? Also, the bolt head says 10.9. Is this a fairly common size that I would be able to pick up at an autoparts store? Should I avoid driving at all costs until this is fixed? I don't know if I am doing any major damage by having 3 wheels on the pro kit and one sitting stock.

Thanks in advance for any advice!


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Old 04-20-2009, 10:10 AM   #2
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Absolutely do not drive the vehicle. You didn't say where the bolt was located. Drilling out the bolt sounds like the only way you are going to solve your problem but it would help if you indicated which bolt it is.
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Old 04-20-2009, 10:50 AM   #3
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Or find you a punch that is a little smaller than the bolt and try to knock it out if you have enough room . Just be sure and have some type of support under or around it just in case something drops.
But most of all ,
DO NOT DRIVE IT !!!
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Old 04-20-2009, 10:53 AM   #4
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sorry i didnt specify the bolt, I don't know all the terminology (just learning suspensions) but it appears to be the bolt that connects the lower control arm to the brake assembly.
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Old 04-20-2009, 11:00 AM   #5
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that bolt is the hardest to get out for sure.

put a ton of liquid wrench on the bolt and let it sit to soak into the threads. drilling it out would be the safest. use a left hand 5/16" drill bit. (I guseed at the drill bit size so check it first) use a strong drill at about half speed. it should start to pull it out after awhile of drilling.

before re-installing the new suspension. thread the new bolt in the nut a little bit then turn it back n forth, in a little more, back n forth. that way you will clean the threads up before thr install.
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Old 04-20-2009, 11:59 AM   #6
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I agree with norcal on that one. This isn't an unusual problem. Our cars get really dirty down there and it is subject to all the weather so they will be very hard to get out in most cases. I know this sounds like hind sight but anytime you work on replacing any components on the suspension or anything else in the undercarrage use liquied wrench before you do anything. Let is soak for a good period of time and never try to force it. I know that doesn't help your situation now but I hope it helps for any future mods or repairs you do...
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Old 04-20-2009, 12:13 PM   #7
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Don't leave out liquid wrenches good buddy PB BLaster they go hand in hand with rusted nuts and bolts :)
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Old 04-20-2009, 12:43 PM   #8
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If it the lower control arm bolt, most people end up cutting the bolt on each side of the bushing with a Sawzall, Die Grinder, hacksaw... and buying a new lower control arm. Mike from Hilbish Ford can ship one to you for a nice price, in case your dealer is asking too much. http://www.focusfanatics.com/forum/showthread.php?t=142732
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Old 04-20-2009, 01:54 PM   #9
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i bought a replacement bolt from a local ford dealership today, I'll try drilling the rest of the old one out and hopefully that will solve my problems, and i can avoid having to purchase and wait for a new LCA.
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Old 04-20-2009, 04:00 PM   #10
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With regards to drilling. Sometimes its easier to use a smaller bit to start then follow with one almost the same size. That bolt is supper hard and sometimes the larger bits don't always start cutting easily. Use a slow to moderate speed to start and occasionally oil the tip to keep the bit cool and clear shavings. A new (read sharp) bit is advisable as well.
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