When I took my T5 out, as I was unscrewing the bolts, each one(4) broke well before it was all the way out. This happen to anyone else? So now im just gonna weld a section of screw to the broken off parts and use nuts to tighten the cross member. Bad idea? I am not about to lay under there and try to get the rest of them all the way out.

 

I had 2 break on me on the same side. I successfully drilled one out, but the other one was hopeless. I just ended up drilling a new hole and tapping it. It isn't as strong as the other ones, but I still have 3 good bolts holding it up. The one that is drilled is still pretty strong, just not as strong as the others. In your case, if you can't drill them out, you might have to cut that section of the subframe out and weld in a new piece with nuts welded to it.

 

That sucks! I've never heard of that happening before. Did you put some kroil or liquid wrench on them before you tried loosening them? Sound like my luck though.

I would take whatever steps necessary to do a proper fix for it. I don't think I'd weld studs on. Seems risky. I wouldn't risk something that won't hold there, it could be catastrophic for you or others on the road if it failed.

You may try drilling them out and making a plate with nuts that you can slide back in the frame rail over the holes you drilled out. They're are holes in there big enough to get one in the frame rail. Then bolt new bolts the same size through there. They did that in hot rod or car craft back in 94 when doing the aftermarket T56 swap in a camaro since the crossmember didn't line up right and no aftermarket crossmembers were available yet.
Good Luck!