So, I bought my 96 Disco SD not long ago. I plan on having my kids in quite a bit. I have a front facing car seat and a booster.
Anyway, one of the seat belt receivers was being held together by duct tape. I ordered a replacement and went to install it. It looked easy enough. 1 Torx bolt. I soaked it in PB Blaster and promptly stripped it.
So, I decided before drilling it all the way through, to try a bolt extractor. I broke off in the bolt, so now I can't even drill it out because the metal of the broken extractor is too hard.
I then tried cutting a groove in the top of the bolt and hitting it axially with a hammer and chisel. It didn't budge.
I tried to attack from underneath, by getting a wrench on the nut from the bottom. It is welded to the bracket.
So what next? Cut off the nut with a cut-off wheel? Any better ideas?
Such a nightmare...

 

Flip up the seat and remove the whole seatbelt and then replace the whole thing.
That would be your best bet I bet.
www.autosportsunlimited.com
www.roverlandparts.com

 

Spike, That is what I am attempting to do. I am trying to remove the Torx bolt that attaches the two seat belt receivers to the body of the truck.

 

Got it, I thought you were trying to replace the buckle not the whole thing, sorry.

I have no idea, I hate torx head bolts, they always strip.

 

Yes, I have a new hatred unlike any that I ever imagined I could feel for a fastener.

 

At least you can still drive it, I was trying to replace the thermostat on my wifes Volvo and they use torx bolts, aluminum ones at that.
I wound up using a bigger head bit to get them out and then replaced them with standard hex head bolts.
And you have to use a 6" extension and a wobble attachment so you have like no torque to remove the damn things.

 

what is the head of the bolt like? I am sure it is tapered slightly to where the torx bit would go in but if you can get a pencil torch on the welded nut on the back and a pair of vice grips on the head of the bolt that may work. Its amazing how much a nut will expand when you need it to!

 

had a similar situation on mine....turn out that the "loctite " or whatever they used on the bolt threads is some heavy duty stuff and the only way to get the threadlocker to release is to heat the bolt or nut, of course you dont realize this till you've already ruined the bolt head or broke a couple of sockets, I had one that I had to wet down the carpet and mig weld a new nut to the top of the old one -- and it came right out.....just a last resort trick if need be
good luck !

 

Thanks guys, I think I am going to try a combo of welding a nut on and heating the nut that is under the truck.
Hope I don't get to close to the gas tank!!!!