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2008 Highlander Battery Post Bolt Snapped #5333829 01/27/20 02:31 PM
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maverickfhs Offline OP
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As the title suggests, had a friend and they were doing a battery change and one of the 10mm bolt to hold battery in place head snapped.

Without drilling, is there any other work around to extract and replace with a new on? Thank you thumbsup

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Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5333835 01/27/20 02:38 PM
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Donald Offline
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The proper way is to drill it out. Preferably with left hand drills and a good soaking with PB Blaster or similar. Some will weld a nut on what is broken and get it out that way.

Part of that bolt is probably rusted or corroded.

You do not want the battery bouncing around where its two posts could contact the hood for example.

If there is a nut down there that is spot welded in place you could grind the spot welds and then use a new nut held with a wrench to tighten.


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Re: 2008 Highlander Battery Post Bolt Snapped [Re: Donald] #5333836 01/27/20 02:40 PM
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maverickfhs Offline OP
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Originally Posted by Donald


If there is a nut down there that is spot welded in place you could grind the spot welds and then use a new nut held with a wrench to tighten.


Thank you, yes there's a small nut spot welded there.


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Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5333875 01/27/20 03:20 PM
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The torque on those is about 70 in lbs so they are easy to break.

Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5333888 01/27/20 03:31 PM
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I would simply drill it out then put a different bolt in there, and spin a nut on the back of it.

Should be secure.


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Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5333894 01/27/20 03:45 PM
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since it has a nut spotweld on etc. they usually aren't too hard to knock loose with a hammer chisel.

once you get it out you could run a carriage bolt through the bottom and nut it on top which might make it easier to tighten back up.


I'd buy Callahan autoparts if I could.
Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5333897 01/27/20 03:48 PM
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If any of the old bolt is visible on the other side of the welded nut and if you can get to it, generally the broken piece of bold will unwind from that side.


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Re: 2008 Highlander Battery Post Bolt Snapped [Re: kschachn] #5333901 01/27/20 03:50 PM
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maverickfhs Offline OP
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Originally Posted by kschachn
If any of the old bolt is visible on the other side of the welded nut and if you can get to it, generally the broken piece of bold will unwind from that side.

Yes we could tighten up a nut from the other/downward visible side, question is should we be tightening up that nut and eventually the remainder of the broken bolt would come out?


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Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5333949 01/27/20 04:47 PM
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LeakySeals Offline
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Originally Posted by maverickfhs
Originally Posted by kschachn
If any of the old bolt is visible on the other side of the welded nut and if you can get to it, generally the broken piece of bold will unwind from that side.

Yes we could tighten up a nut from the other/downward visible side, question is should we be tightening up that nut and eventually the remainder of the broken bolt would come out?

Can you get the battery out of the way so you can bite whats left and pull it out from the back?


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Re: 2008 Highlander Battery Post Bolt Snapped [Re: kschachn] #5333996 01/27/20 05:33 PM
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Originally Posted by kschachn
If any of the old bolt is visible on the other side of the welded nut and if you can get to it, generally the broken piece of bold will unwind from that side.


If it's part of a battery tray it's probably seen acid and corroded. The suggestion to just drill through everything and put another nut & bolt holds water.

Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5334045 01/27/20 06:21 PM
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bullwinkle Offline
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Last time this happened I just drilled & tapped the hole, stuck a spare bolt in there (with lots of antiseize on it).


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Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5334123 01/27/20 07:29 PM
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Originally Posted by maverickfhs
Yes we could tighten up a nut from the other/downward visible side, question is should we be tightening up that nut and eventually the remainder of the broken bolt would come out?

What I meant was that a lot of the times the reason a bolt snaps off is because the protruding threads on the other side of the nut are rusted. When you try and unscrew the bolt the rusty threads hang up and the rest of the rusty bolt snaps off. So if the remaining bolt piece is still protruding from the back side, generally you can unscrew it from there and back it out of the nut.

You don't need to add another nut or tighten up anything, just unscrew the broken off bolt from the other side. All of which assumes you're able to grab it however.


1994 BMW 530i, 251K
1996 Honda Accord, 280K
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Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5334134 01/27/20 07:40 PM
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Thread title suggests that the broken bolt is on top of the battery.

Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5334230 01/27/20 09:05 PM
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The bolt goes through a thin tab on the radiator support. Might be enough room underneath to grab with some visegrips & turn it out

Re: 2008 Highlander Battery Post Bolt Snapped [Re: maverickfhs] #5334234 01/27/20 09:07 PM
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