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Broken bits on 4x4 hub

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Old Mar 24, 2024 | 06:49 PM
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Broken bits on 4x4 hub

I just bought myself a 94 f150 4x4 but the whole front end is pretty messed up and just about every bushing is shot.

I’m currently trying to do the ball joints but I have broken atleast 10, #15 torx bits trying to loosen these 4x4 hubs. I’ve used zep and other pen oils to no avail… I really don’t want to drill these since they aren’t stripping but just instantly breaking my tips. I can’t go any further without getting them off, any tips would be huge. Thanks in advance
 

Last edited by Zweiday; Mar 24, 2024 at 07:04 PM.
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Old Mar 24, 2024 | 07:50 PM
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You might need to drill the heads if trying to tighten the screws doesn’t break them free.
 
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Old Mar 24, 2024 | 08:01 PM
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Originally Posted by My4Fordtrucks
You might need to drill the heads if trying to tighten the screws doesn’t break them free.
Is it not too bad drilling them? I just don’t want to mess anything up
also from googling replacements I just don’t know if they’ll fit all I can find is Allen heads
 

Last edited by Zweiday; Mar 24, 2024 at 08:05 PM.
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Old Mar 24, 2024 | 09:34 PM
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Originally Posted by Zweiday
Is it not too bad drilling them? I just don’t want to mess anything up
also from googling replacements I just don’t know if they’ll fit all I can find is Allen heads
Do you have a hammer drill with hammer mode only, or an air chisel?
If you rig a torx head bit on to either one, or even a small tipped pointed chisel, you can vibrate the screws for a while, without trying to turn them, then after vibrating them for minutes each, try breaking them loose by hand. It might work.
Vibrate them about twice as long as you think it'll take. Eventually that vibration will loosen them.
 
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Old Mar 24, 2024 | 11:20 PM
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Originally Posted by Soup bean
Do you have a hammer drill with hammer mode only, or an air chisel?
If you rig a torx head bit on to either one, or even a small tipped pointed chisel, you can vibrate the screws for a while, without trying to turn them, then after vibrating them for minutes each, try breaking them loose by hand. It might work.
Vibrate them about twice as long as you think it'll take. Eventually that vibration will loosen them.
I do have one, I’ll give that a go is PB blaster worth it?
 
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Old Mar 24, 2024 | 11:25 PM
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Originally Posted by Zweiday
I do have one, I’ll give that a go is PB blaster worth it?
Yes, PB blaster also.
Just don't marr up the torx head grooves while vibrating.
 
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Old Mar 24, 2024 | 11:30 PM
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Originally Posted by Soup bean
Yes, PB blaster also.
Just don't marr up the torx head grooves while vibrating.
definitely, I’ll try the smallest pin I have, hopefully it works, maybe I can weld a t15 to something and hit it. I ordered some screws from auto zone as well in case I have to drill them. This thing needs a lot of love, I bought a new steering box, and tie rods just waiting on those excited to learn
 
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Old Mar 24, 2024 | 11:35 PM
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Originally Posted by Zweiday
definitely, I’ll try the smallest pin I have, hopefully it works, maybe I can weld a t15 to something and hit it. I ordered some screws from auto zone as well in case I have to drill them. This thing needs a lot of love, I bought a new steering box, and tie rods just waiting on those excited to learn
Yeah, after a certain amount of time, you might have to drill them out if they just won't loosen.
 
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Old Mar 25, 2024 | 06:42 AM
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Do you have three screw hubs?




 
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Old Mar 25, 2024 | 06:46 AM
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If it were me, I’d try soaking them a few times a day with Aero Kroil while tapping the hubs for a week, not beating on them.. just gently, a little bit to get some vibrations to help the oil creep in a bit. Then give them a try.

Ive not had luck with torx bits, even using impact bits, and an impact gun. The only time I’ve used torx bits and impact were on bed bolts. The torx bits just broke. But, those are pretty small, it might work.

Failing that, as above, drill the heads then soak them and take them out.

Good luck with it.
 
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Old Mar 25, 2024 | 07:14 AM
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Try a little heat ,directed at the hub right behind the cap were the screw goes .also a sharp punch put at direction of loose and tap it while someone is trying to turn the screw
 
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Old Mar 25, 2024 | 08:16 AM
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Drilled several myself over the years
Then just get a 3k104? small parts kit for each hub with the new bolts and o rings, circlips etc.
They drill easy
 
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Old Mar 25, 2024 | 08:54 AM
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Originally Posted by My4Fordtrucks
Do you have three screw hubs?

it’s the superwinch 6bolt


 
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Old Mar 25, 2024 | 08:55 AM
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Originally Posted by JJF20
If it were me, I’d try soaking them a few times a day with Aero Kroil while tapping the hubs for a week, not beating on them.. just gently, a little bit to get some vibrations to help the oil creep in a bit. Then give them a try.

Ive not had luck with torx bits, even using impact bits, and an impact gun. The only time I’ve used torx bits and impact were on bed bolts. The torx bits just broke. But, those are pretty small, it might work.

Failing that, as above, drill the heads then soak them and take them out.

Good luck with it.
thanks for the ideas, I’ll be doing that this week, I think it’ll be a great idea to just see if it eventually works in by the time I get to it next
 
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