Help! Core Support Mounting Bolt head rusted completely off

[Buckethead03]

I am in the process of swapping my cancer filled cab and front clip with one with no rust and have run into a problem. The head of the drivers side main core support bolt(the one that goes through the frame rail) has rusted completely off. All that is left where the bolt head used to be is a mound of rust. What options do I have for removing the bolt without damage to the frame? I can't get a drill in there to drill the bolt out.

[70 ranger]

Can you just pull the cab off then tackle the bolt?

[basketcase0302]

If you already have the core support out of the way a cutting torch will be your friend here. Keeping the heat aimed at the bolt-it will heat and can be blown out of the hole. Getting it out with the core support still there...I'd say dremel tool / remove the core support / then torch the remnants of the bolt out.

[dunn71]

I had the same problem on my truck. What I did is used a grinder and ground off what was left of the bolt, and took a hammer and a punch and drove out the old bold. I hope this helps.

[basketcase0302]

The head of the drivers side main core support bolt(the one that goes through the frame rail) has rusted completely off.

I don't see how you could possibly get a grinder into the area?

[Buckethead03]

yeah its pretty tight in there. After doing a little more looking, the entire area around where the bolt is located is completely rusted away. I guess the only thing holding the front clip on is the support bolts at the firewall. the fender bolts in the door jamb were both loose and the lower fender mounts are rusted away, so the fender just flaps in the wind. I was going to try to remove the front clip as one piece, but i may have to take everything apart piece by piece now.

[SixManCab]

I used a sawzall and cut through the mount (bolt) from the front (with the bumper off). It takes a long time to cut, and was not a lot of fun. I finally took the torch and melted the rubber isolator off (which helped gain access to the bolt).

[sargentrs]

My cab support and core support bushings had the inner pipes rusted together. I used a couple of screwdrivers and pulled the rubber donuts off the bottom of mine. It took some patience and effort but with 2 really big flat head screwdrivers and a claw hammer they peeled off pretty easy once I got one side over the washer.Once you get the bottom donut off you can cut it in half easily with a cutoff wheel on a grinder and lift the core support off where you can get to it better.