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Tue Apr 15, 2025 10:16 am

Hi

Have a 77 dual cab. It has had some interesting repairs over the years. The rear shock was damaged so I have tried to replace it. The outer nut had been welded on so I managed to remove that. The bolt itself was welded where it enters the bodywork. After some considerate manipulation it came free, surprisingly easily. That was because the PO had cut the end off a bolt and just welded the bolt in. This is because the original bolt had snapped off in the impossible to access captive nut inside the engine bay.

Does anyone have any ideas as to how I can remove this bolt stub?

Thanks.

Tue Apr 15, 2025 10:52 am

You aren't the first, lots of ways to deal with it here: https://www.thesamba.com/vw/forum/search.php?searc..._chars=200

Tue Apr 15, 2025 5:01 pm

well the question is whether the captive nut is still in place. If it is you should be able to center punch it, drill it carefully and tap it slowly with oil or cutting fluid. A little tiny bit at a time so not to break the captive nut loose. It may be that the PO welded in a stud and used a nut on the end to hold the shock down. If so, I would leave it that way for now.

Thu Apr 17, 2025 2:35 am

Thanks all. Access to the captive being somewhat restricted for anyone with hands, I took the plunge and drilled out the remaining bolt shaft.

After much amusement I have managed to insert a new bolt and using witchcraft I eventually managed to get the nut to bite.

Onto the next issue.

Cheers.