foxfire256

So I noticed one of the bolts on the front, driver's side sway bar bracket is broken. Should I drill it out and tap it for a bigger (10mm?) bolt or should I try to remove the existing one somehow?

2001.5 S4
175k miles

Pete@ECSTuning

It's hard to see in the picture - how much of the bolt is exposed? Would soaking it in PB penetrating spray and using a pair if vise grips on it be a viable option? I despise drilling out bolts.

foxfire256

There is about 1/4" exposed. I'll give that a try when I get a chance.

Pete@ECSTuning

Let the penetrating catalyst soak for some time before trying to break it free.

jamesdmanley

you can also try a reverse threaded drill bit, ez out type tool, or cutting a slot in the exposed bolt and using a flat blade screw driver to remove after pb'ing it up

MikekiM@PureMS

Those aren't bolts. They're studs which are pressed into the aluminum. To remove it you either have to press it out, or drill it out.

Best to drill it out, and replace it with a normal nut/bolt combination.

jamesdmanley

in that case, +1

Pete@ECSTuning

Good call!

Homegrown-MN

This is an old post, but because others may experience this too it seemed worthwhile to comment. On my A6 the nut broke off leaving the bolt/stud in the car. Luckily, it was the rear position of the sway bar bracket and accessible.

I simply tapped it out. The bolt has a round top and is smooth...so now tool will remove it. However, it was simple to replace by dropping in a new bolt which didnt even spin when I tightened the nut.

Total time working on it = 5 min. Total time researching it before trying to tap it out = 3 hrs. Hopefully, this will save someone else time and money. Those bolts arent very good if I can twist it off.