Suggestions on removing snapped bolt holding on back bumper

[dan5150]

It was bound to happen to me on a 25 year old Jeep, and yesterday it finally did.

I am trying to replace the stock rear bumper and small tow receptical with an aftermarket tubular one, on my 1999 TJ Sport.
I want to upgrade the looks, plus the PO had clearly backed into a pole of some sort and bent it in.
I looks like there are 6 total bolts holding it on, 2 on each side going directly into the frame and 1 on each side going up from the bottom into the frame.
The last one, was a pain as the exhaust pipe is right in the way of the wrench, but I managed to negoicate it, and when using the breaker bar to loosen it, snapped off the head.

So. Looking for suggestions on how to get this thing off. Do I need to take it to a body shop and have them cut it off with a torch? I have a recipricating saw, but I am not sure I have bladed that will cut through that steel tab attached to the bumper. (Although honestly I haven't tried yet).

The first 2 pictures show where the broken bolt is. The third just shows where the bumper is crunched against the frame.

 

[MountaineerTom]

Do you have the clearance and are able to remove the rest of the bumper and hitch with it snapped off like that? If so, you should be able to grab it with a big pair of locking pliers (vice grips). I would spray some penetrating oil on the threads and let it soak some before trying to turn it though. Something besides WD-40. Kroil is great but pricey, PB Blaster is ok. A 50/50 mix of automatic transmission fluid and acetone is great as well. If you can heat the remainder of the bolt up with a torch, or even one of those yellow bottles of MAPP gas, it would help.

You may still be able to grab it with vise grips since there’s some sticking out. It needs the penetration oil as often as you can though before hand.

 

[dan5150]

Thanks for the reply. Unfortunately, there are 2 more bolts for the rest of the hitch that go directly into the frame that are behind the bumper. I have kriol, but I can’t get to the other side of the bolt to soak it. I don’t have a torch. What’s MAPP gas? Is that like a propane plumbing torch?

 

[macleanflood]

What’s MAPP gas? Is that like a propane plumbing torch?

Yes but with a yellow bottle.

Might be time to invest in a cheap HF welder. Weld a washer on the stub, then weld a bolt on the washer.

If you're not keeping the original bumper get a grinder and a cutoff wheel or a sawzall and just cut the tab.

-Mac

 

[MountaineerTom]

Thanks for the reply. Unfortunately, there are 2 more bolts for the rest of the hitch that go directly into the frame that are behind the bumper. I have kriol, but I can’t get to the other side of the bolt to soak it. I don’t have a torch. What’s MAPP gas? Is that like a propane plumbing torch?

Yes, they sell it at Lowes. At least they used to. You’d need the little screw on nozzle too.

If it were me, I’d try to spray some Kroil in the cracks of those layers of metal and hope some gets where it needs too. You may also be able to get some through those holes in the frame.

Do you have the little straw for the Kroil?

I can’t remember if there are similarly placed holes on the backside of the frame, but I’d look there and see if you can get some spray in from that side too. Probably a tight fit with the gas tank there though.

 

[CharlesHS]

Thanks for the reply. Unfortunately, there are 2 more bolts for the rest of the hitch that go directly into the frame that are behind the bumper. I have kriol, but I can’t get to the other side of the bolt to soak it. I don’t have a torch. What’s MAPP gas? Is that like a propane plumbing torch?

MAPP gas of today is not the MAPP gas of years ago....
Todays MAPP PRO (Propylene based) gas only heats to slightly over 3700* where the original MAPP (Methylacetylene-Propadiene Propane) gas years ago was rated at 5300*.
I still have one of the original MAPP gas cylinders and use it sparingly.

 

[KennethS]

MAPP gas of today is not the MAPP gas of years ago....
Todays MAPP PRO (Propylene based) gas only heats to slightly over 3700* where the original MAPP (Methylacetylene-Propadiene Propane) gas years ago was rated at 5300*.

A quick internet search says the melting point of steel is 2,500 to 2,800 F, so even the crappy new stuff should liquefy bolts. It might just take a bit longer.

 

[dan5150]

UPDATE: I took @macleanflood 's advice, and picked up an angle grinder and cutting wheel. (Never shy away from an excuse to buy a new tool!) However, I wasn't to get the blade close enough to cut off the tab. However, using a big pry bar, I was able to bend the bumper out enough to to access to the bolts holding on the tow hitch braket, which once removed, enabled me to remove the bumper and hitch assembly.

Thanks to everyone's suggestions! This group and fourm are an awesome resource for TJ owners.

Now on to installing a new bumper....