P1000 Bumper bolts broke off!!

[aauman88]

Well last week when winch motor went out one upper bumper mount bolt broke off. Today I got my new winch motor in and went to take bumper off to install and two more bolts broke off. Seems to be very weak bolts in a bad place. Problem is now bumper won’t come off for me to remove broken studs.

Any ideas how to remove bumper now?? Thanks in advance.

 

[JTW]

Pics!!?

 

[aauman88]

It’s stock LE bumper. The upper bars where they slide into frame have two bolts on each side facing inward. Guessing I tightened them too much last time and stretched the threads and weakened bolts. Snapped right off when I tried to loosen them. I have quit for the night but will snap some pics in morning but all you can see is where bolts are supposed to be.

 

[JTW]

It’s stock LE bumper. The upper bars where they slide into frame have two bolts on each side facing inward. Guessing I tightened them too much last time and stretched the threads and weakened bolts. Snapped right off when I tried to loosen them. I have quit for the night but will snap some pics in morning but all you can see is where bolts are supposed to be.

So, your best bet will probably be to just drill from the thread side and over drill the bolt and nut. Then just run a larger bolt thru and use a nut on the outside. Gunna be a pain in the ass... as I can’t think of an easier way to get in there.

 

[nal3470]

Mine did same thing broke 2 drill bits trying to drilled out so I said screw it take a log chain around tree to bumper 4wd diff lock reverse bump it couple times weld nuts pops off then put couple grade 8 bolts back in

 

[Delton]

Mine did same. Bumper was hanging on what was left of broke bolt. Ended up cutting the square tubing to get it off. Went back with thick wall 1.5" tubing and drilled out holes for 3/8" bolts.

 

[aauman88]

Should that be better bolts considering what it’s holding? Seems like it to me

 

[tjoreo]

That is the reason I went with the KFI winch mount which at least hooks to the frame and not the bumper. The bumpers are just not very substantial and I was actually missing one of the bolts you are talking about from the factory. I wish you luck.

 

[aauman88]

Let me clarify I have the Viper winch mount which bolts straight plate directly to front of frame so it’s not a winch/bumper issue for me. Just seems those bolts would be better grade from bumper to frame standpoint. After seeing this I’m very glad I didn’t buy a mount that bolts winch to bumper

 

[tjoreo]

Okay I understand. I actually ordered a factory replacement to replace the one I was missing, but I might just upgrade to a better bolt. When I installed my plate I upgraded to 10.9 bolts to install it. Might just get 4 new ones.

 

[sharp]

You could try a broken bolt extracter kit. I think orileys or lowes may have them.

 

[aauman88]

Bolts out and tacked nuts off. Drilled for 3/8 bolts but have no clue how to get to back of them now to put nut and lock washer on by myself. Got winch back in and it’s working. Also added the bumper tabs for shackles. I bolted it as close to the bumper mount as I could so we will see how it holds up and it does have a backer plate. Lower bumper bolt threads are screwed up so have to get new bolts tomorrow and rethread the nut. Buddy will come tomorrow I hope and help me bolt bumper back on

 

[JTW]

Just run bolts all the way thru and skip re threading.

 

[aauman88]

Think I will throw bumper away if I have to take it off again, lol.

Side note: this came out from under Honda when I was knocking the nuts off frame and I don’t see where it goes. Any idea?
Thanks

 

[JTW]

Back of the headlight housing

 

[aauman88]

Back of the headlight housing

Thanks

 

[aauman88]

Got bumper off and removed nuts from frame. Drilled out and out in grade 8 bolts with nuts on back. Have to remove the winch hawse to access nuts on backside but hopefully I won’t have to do that often. Lower mount got new bolts too and threads on nut were perfect. The nuts are good quality but they use s***ty bolts. Added frame stiffener as well so hopefully I’m ready for the weekend.

 

[DDDonkey]

Good looking rig!

 

[aauman88]

Good looking rig!

Thanks

 

[DevinCoulon]

Bolts out and tacked nuts off. Drilled for 3/8 bolts but have no clue how to get to back of them now to put nut and lock washer on by myself. Got winch back in and it’s working. Also added the bumper tabs for shackles. I bolted it as close to the bumper mount as I could so we will see how it holds up and it does have a backer plate. Lower bumper bolt threads are screwed up so have to get new bolts tomorrow and rethread the nut. Buddy will come tomorrow I hope and help me bolt bumper back on

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Man I hate to bring up an old thread but I’m fighting the exact same problem with the broken bolt. How did you end up getting it out? Did you just drill all the way through? Thanks in advance..