So I was replacing my transmission mount (which was totally ripped in half) and I noticed my crossmember was only held in by 3 bolts, as the fourth one on the driver side head was missing. I then undid the passenger side, and started to undo the only bolt holding in the crossmember on the driver side. To my chagrin the head popped right off. Any ideas how to fix this? I have two bolts without heads stuck in the driver side subframe where the crossmeber is supposed to be. Any ideas how to fix it?

 

Extractor kit, and PB Blaster. Spray the beheaded bolts with PB Blaster every day for a few days to make sure it penetrates the threads. Then an extractor kit should remove the bolts - extractor is reverse threaded, and conical - you drill a small hole in each bolt, and as you install the extractor, it embeds itself further into the bolt, while turning in the reverse direction - eventually the bolt with start turning (out) rather than the extractor turning in farther. Available at any hardware store/Home Depot.

 

I would use a set of left handed drill bits, I've never had any luck with extractors. It's the same principle, the drill bits seem to work better though. You start with a small bit and drill directly in the center of the broken bolt, then work up in sizes until the old bolt spins right out. I think the bits work better because you can remove enough of the old bolt's material and relieve the pressure actually holding it in. Extractors or easy-outs actually put more pressure onto the bolt as you tighten them (or is that loosen??). The LH bits cost more, if you've ever broken an extractor off you'll never go back.

I also live in michigan and have ran into this same problem of broken crossmember bolts on both of my fbodys. I've just cut out the problem bolt with a grinder, making a nice square hole. Then I tack weld a nut onto a piece of plate steel that roughly matches the hole left by grinding. Bolt up the crossmember, make a couple of tack welds to hold the new nut/plate. Drop crossmember, finish welding plate and it's good to go.

 

I just gimped the car to an AAMCO and made it their problem... only cost me $50 and once again it doesn't hurt too much to drive. Thanks for all the advice!!! Nice to know I'm not the only one with these problems.