Crossmember bolt stripped out...

[eclipsegsx1736]

Well, there's a reason I do almost all the work on my car myself. I didn't feel like attempting a tranny rebuild, so I took it to my trusty DSM mechanic which I have had awesome luck with in the past. I got the car back and it shifted very well, but it make this clunk and creaking when I would let out the clutch. I brought it back and he told me that when he put the crossmember back in (black brace you use to jack up the front of the car, also holds front motor mount) that one of the bolts that holds the crossmember to the chassis/radiator support area got stripped, so the crossmember was holding being held with one bolt. I jacked up my car from the crossmember, and it made the exact creaking sound, and I could see the crossmember was being pushed back up to meet the chassis, so it was infact sagging. Well I temporarily tightened the other bolt that was still good as tight as possilbe, and the creaking went away, but it still makes a nasty thud if i let off the gas and get back on. Basically any time the car jerks back and forth I hear a nasty thud/knocking sound as if the engine is slamming around. I can't floor it in 1st or shift hard into 2nd without it making this sound.

I obviously need to replace this bolt, but when I tried to use another clean bolt to thread in, it wouldn't thread. So whatever is on the other end (I suspect it's a nut welded to the other side of the radiator support/chassis) is also stripped out. He told me I need to take it to a body shop and have them cut the chassis support there, and bend down a section and weld a new nut there, and I should be good. Has this happened to anyone? Could it be somehthing else, maybe the tranny mount? It's a pretty big bolt that's missing out of the bottom of my car... I need to fix it soon, without spending a fortune. I hope I can find a way to do it myself..Retap? Anyone delt with this bolt/nut area before?

 

[TRBOBLU]

It happened to me but I was lucky and a new bolt fixed the problem. Honestly I would try to use a tap on it to possibly clean up the threads enough to get a bolt in. If you look at the pics you will see why welding a new nut it would be a pain because the factory nut is positioned somewhere inside the support and since you really cant see inside its hard to tell how its connected. Worst case scenario, I would drill a large hole directly above where the bolt goes in and try to see how the factory nut is welded on. Then work from there to do whatever you need in order to get a new nut welded in. I would be weary of bending down a section because it will more than likely tweak your radiator support a little.

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[turbodsm87]

just tap it out and it should be fine. make sure you get the right tap though

 

[motozachl]

My crossmember bolt/stud is stripped and it won't come out, it just keeps on spinning. How would I get this out and repair this? I'm replacing my crossmember with a different one so this needs to come off

 

[95redturboawd]

If the OP is still having that problem, there are 2 more bolts holding the crossmember on that are further towards the back of the car. Only one of my radiator support area bolts is in and there's no play at all in the crossmember. Motozach, you could try pulling down on the bolt as much you can (or get a flathead under the head of the bolt and push it down) so hopefully you'll be able to catch a thread.

 

[motozachl]

If the OP is still having that problem, there are 2 more bolts holding the crossmember on that are further towards the back of the car. Only one of my radiator support area bolts is in and there's no play at all in the crossmember. Motozach, you could try pulling down on the bolt as much you can (or get a flathead under the head of the bolt and push it down) so hopefully you'll be able to catch a thread.

I doubt they're still fidangling with this after 4 years I just didn't want to make a new thread. But yes I tried that to no avail. Any other ideas?

 

[motozachl]

Well I ended up cutting that stud to get it off. So now how would I replace this? What is in frame? I'd like to know before I just start hacking away....

 

[babell2]

OK it will take some welding. Use a hole saw and cut out the affected area. manufacture a replacment plug and weld a nut to the back side. Then weld the plug back into the hole. That is just my suggestion. I have manufactured a replacment bumper support for my car out of rectangular tubing. I sank new nuts into holes in the tube and welded them in place to hold the 5 mph shock struts on from the body. Yes a little heavy but STRONG!

 

[motozachl]

hmmm i can't weld though and the car cannot move. this is what i think the inside of the frame looks like judging by the way the bolt moves. is this correct(bolt it in maroon)?

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[babell2]

Yes it is a bolt with a T head or some sort of capdevaded device to keep it from turning. I think it is a loose fit to allow alignment of the lower brace.