Help Replacing Gas Strut Bolt In Boot Of Xr6T

[Jonno]

As I mentioned in the post below, the bolt connecting the gas strut to the body of my 2006 XR6T has rusted. I took to it with the spanners and it came loose - but cannot be retightened. I can just get my hand behind the bolt (behind the boot trim there are some access points) and it feels like there is a bolt or square piece of metal, but I have no way of clamping it (due to limited access) to see if it can be tightened.

I went to the panel beater today and he said the only way to fix it was to drill a hole below the bolt to gain proper access, and then MIG weld it to the body. This seems expensive, and messy (the area will need to be repainted).

Does anyone know an easy way to remove the old bolt and replace it with a new one. Or (sob) is the panel beater right?

Thanks for your help.

Jonno

[Jonno]

Bump.

If no one knows the answer - can anyone suggest where I can find out? I am in the inner west of Sydney.

Thanks.

Jonno.

[hawlass]

Can you pull the bolt out far enough to get 2 or 3 mm of room between the back of the bolt and the body?

If so, I'd have a go with a dremel and a cut off wheel ( these are only about 1mm thick). Make sure to cover the surrounding paintwork with some gaffa tape in case of a slip, and a few old sheets around the general area to protect from iron filings rusting later on and marking your paintwork.

Once out I assume you can get at the back to fit a new nut on the new bolt?

Good luck, and make sure to write up a how to thread once you finish, as I think you wont be the last with this problem.

[Jonno]

There is no way to get to the back of the bolt.

Jonno

[hawlass]

I meant between the part of the bolt the strut attaches to and the body,the side you can see, not the back(inside)

[Jonno]

I just had a quote of $600 to replace the bolt. Surely there must be a better way???????????

Jonno

[bjc]

Let me have a look tomorrow for you mate but surely there is a way (probably cheaper than $600 also!)

No guarantees but I'll look anyways.

Otherwise I was just thinking you could use a cutting wheel to get so far then a grinding wheel and give it a good tap and it should fall inside the body. Replace with a new one that will need to be tack welded though to stay in place. But then theres the old bit stuck in the frame somewhere to deal with!

[bjc]

Well remembered to take a look at this today and there is access via the boot. Took some photos which are a bit dodge but you should get the drift. The access is via the oval hole closest to the back seat and there is enough room (over 2in x 6in) for a small to medium pair of needle nose pliers.

There is a thread on the nut but no edges for a spanner as its tacked to the body as can be seen in the photo so that's why I'd reccommend the vice grips and a spanner on the ball joint to undo.

Hope this helps even if a little late!

Brett