I want to remove my nudge bar due to it being rusted and bent. I cannot get a normal allen wrench to fit the side supports and the instructions do not list the allen key size. Does anyone know what size it is? I am betting on 5/32 but even that has been tough to turn.

FYI 1st post - new owner of a 2004 D2, 99k miles and no codes, leaks or issues...yet...

 

It will be metric, not SAE...

 

I purchased a used one last summer and it had rusted bolts in the corners and I had to drill them out and then re-tap the treads. I used some new stainless steel bolts from the hardware store.

 

The thought of drilling that close to the fender doesn't have me thrilled since I don't think you can take the bracket off while it is connected to the bar.

This will be an "after the wife goes to sleep" operation

 

Can you grab the head of the bolt with a small vice-grips and get it out that way? Might try some PB Blaster on it first.

 

+1 on PB Blaster (allow to soak overnight). The bolt is round headed, so hard to grab, but not impossible. The Allen is Metric 3.0