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Broken front sway bar bracket bolt, any ideas?

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Old Oct 13, 2010 | 10:03 AM
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Default Broken front sway bar bracket bolt, any ideas?
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
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Old Oct 13, 2010 | 11:00 AM
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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.
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Old Oct 13, 2010 | 11:46 AM
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There is about 1/4" exposed. I'll give that a try when I get a chance.
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Old Oct 13, 2010 | 12:07 PM
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Let the penetrating catalyst soak for some time before trying to break it free.
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Old Oct 14, 2010 | 05:59 PM
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From: houston
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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
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Old Oct 15, 2010 | 08:41 AM
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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.
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Old Oct 15, 2010 | 11:42 AM
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Originally Posted by 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.
in that case, +1
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Old Oct 15, 2010 | 01:02 PM
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Originally Posted by MikekiM@PureMS
Those aren't bolts. To remove it you either have to press it out, or drill it out.
Good call!
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Originally Posted by 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.
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.
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