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mark13



Member Since: 16 Apr 2018
Location: Essex
Posts: 56
United Kingdom 2004 Defender 90 2.5 TD HT Cairns Blue
Rusted off bolts on tow hitch
I tried to remove the old tow hitch plate from the rear cross member today and could hardly move the 2 main bolts so I got my long torque wrench out and the bolts started to undo for about 10mm then just span. This happened on both bolts, I guessed I snapped off the welder nut but at the back.
Then I tried to remove the 3 bolts from the underneath plate and these just snapped flush with the surface. In the end I got the grinder out and took the heads off the two loose nuts and off came all the tow hitch assembly.
I want to put a NAS step back on it, then put the hitch back on but how do I remove the 3 sheared bolts underneath and have the ability to bolt the 2 large rear bolts on. The rear cross member is actually in really good condition I can’t really see any surface rust let alone structual rust.
Post #715334 30th Jun 2018 3:47pm
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sako243



Member Since: 08 Jul 2014
Location: Wales
Posts: 1231
Wales 1994 Defender 110 300 Tdi CSW Alpine White
The bottom bolts are in tapped threads so no real option but to drill out the centres. I have historically had some success with drilling it out to under the shank size and then with a chisel or sharp screwdriver knocking the remaining bolt thread into the hole.

Not sure on the big bolts, I haven't had a standard cross member on my 110 for a while and when it was replaced it was cut off so was able to access both sides. Ed
82 Hotspur Sandringham 6x6
95 Defender 110 300Tdi
Post #715335 30th Jun 2018 3:52pm
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mark13



Member Since: 16 Apr 2018
Location: Essex
Posts: 56
United Kingdom 2004 Defender 90 2.5 TD HT Cairns Blue
Some part of me just thinks this is wrong, but a weld is meant to be as strong as the original metal, I have a mate who is a professional fabricator (ex aerospace). What are people’s thoughts on cutting the front section with the nutless holes out (just the front plate) and putting the section back with the holes and nuts behind. Nic the welder is extremely good, but he is away this weekend so I cant ask him. It just feels slightly wrong to me but what do people think.
Post #715467 1st Jul 2018 11:18am
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Balvaig



Member Since: 19 Feb 2016
Location: Fife
Posts: 732
Scotland 2016 Defender 90 Puma 2.2 Landmark LE Corris Grey
Just had a quick look at mine ( LR standard tow fitment). The big bolts look to go into a tapped thread in a pretty hefty plate behind the crossmember. This plate has three vertical tapped threads to adjust the tow hitch.
If yours is the same then you could perhaps re tap the threads after removing the remains of the big bolts.
Post #715490 1st Jul 2018 2:10pm
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