Anyone doing the "rear cab door replace brittle door latch cable ends with cnc'd metals replacements" job, my last bottom screw rounded out. So frustrating. Make sure you crack loose all the black round torx head bolts first [as I'm not doing with all future projects] that way you know you can get them loosened off before you strip or round off the torx bit.Think I realized why the last bolt always gets stripped, bc the materials to make the tools and the nuts n bolts suck, so the tools get worn and it's just enough that the cheap soft material is the nuts n bolts round off too. Hence, there's not a fkn problem. So aggravating. They should just make stuff right instead of skimpin. Cheap f*ck*rs. Trying for extreme profits effects other people's productivity.

So how would you get one of fnckers out that has been rounded off on the inside and cant grip on outside either? I've been chasing my tail with different methods, and nothing grabs ahold of it good enough.

 

Hmmm…

Cut a groove in it with a dremel and use a flat head screwdriver on it.

Drill the head and body out.

I had a couple troublemakers between my ‘03 and the company ‘04H. I think I just got enough grip with vice grips and spun them out.

 

I've tried spraying penetrant. I've tried new torx head. There is already play in them to begin with. The problem also is that its on the underside of the outer part of door. So hammering something in is difficult upsidedown. but also the give of the door bouncing up n down. Grrrr
I'm gonna try cutting grooves and large flathead as suggested by Johnny Paycheck [https://www.f150forum.com/members/jo...ycheck-311399]

 

Screw extractor / easy out style kit. I've had good luck with this set off Amazon. I've used it on Torx bolts with success on my snowmobile.

 

Diamond tip (shape not material) chisel and a hammer.

 

Take a file and flatten opposite sides and then use a wrench on it.

 

I've tried these, no bueno. I think the material used to make the bolts along with the rounded tapered shape def do not help and give way so the bit just spins and doesnt bite.

 

*Finally got it. Had to cut slots into it with a rotary tool and use a flathead screwdriver. 2 days spent chasing action for the last piece and set of bolts overall. Grrrr
Thx to all for suggestions.

 

Glad you got it taken care of.

 

me too buddy, me too. such a huge pia. always good to learn something tho. I'm leaving post up for others that may get something from it.