Sway Bar stud spinning?

[Fiat88]

I'm replacing the 4 bushings on the front sway bar but came to a problem. I was able remove all the 13mm mounting nuts except for one of the inner ones(drivers side), the weld broke and the stud keeps spinning. The only way I can see to get the nut off is if I grab the remaining part of the stud with vice grips.Anyone have some other tricks?

Also, whats an alternative to welding the stud into place when I get the nut off, don't have access to a welder, would JB-Weld work? Thanks.

[v6spider]

Best way to fix it is to weld it...although if you cut the stud completely flush to the frame you could punch through drill all the way through the frame and put bolt through the frame entirely. The only concern I have is weakening the frame by drilling it.

Visegrips will be the only way to grab the stud. Preferably needle nose under the nut. If you can't grab it then cutting with a hacksaw might be the only way to remove it.

[Curly]

Without access to a welder, I'd be cutting the troublesome nut and stud off with a die-grinder/angle grinder then punching the rest of the stud back into the chassis frame. You could then redrill the hole to take a 'rivnut' which is a captive nut that gets inserted in a similar means to a pop rivet. You can then install the sway bar using a bolt instead of the stud and nut.
http://www.rivetnuttool.com/

[v6spider]

That's a good option ...

Rob

[Fiat88]

I ended up refinishing the sway bar by sanding the rust off and POR-15 it. It came out looking new!

I did reinstall it with the new bushings with the intent on bringing it to a mechanic to get a new stud welded on. I do notice a slight creek when I press down with my weight on that side of the car, so I guess thats because the drivers side mount is only held on by one stud or could i have tightened the mounted bolts too tight. I did the final tightening with the weight on the car.
I've only drove the car once around the block because had a coolant leak but first need to get an alignment done and the sway bar stud fixed before I'll feel comfortable. Is it ok for the center mount to be only held by one stud or is it best if I loosen it so the other stud doesn't break. Thanks.

[Fiat88]

Tuesday I plan on bringing the Fiat down to one of the local shops to see about getting a new sway bar stud welded back to the frame and need to get an alignment as I put a good used steering box in and all new tie rods.

What you think is a realistic price to pay just for the stud repair? The hourly rate is around $80 to $90. Any guesses?

[Sunracer]

A couple alternatives for those who may find themselves in a similar spot: wedging and twisting a large flat blade screw driver under the nut. Try to position the stud so it it caught as best as possible in the original weld. If that doesn't work, cutting a slot in the tip with a hacksaw or cutting tool so you can hold it with a screw driver. this will avoid mangling the stud to the point where the nut is hard to get off or has to be replaced. PB

PS you could probably do yourself a favor by removing the front bar before you drive down there, then they won't have to get anything out of the way to weld.

[Oooman]

I had the same problem today. 7 nuts came off the sway bar and the stud turned on the last one.
A nut splitter is the perfect tool to use in a case like this, but not having one handy I used a drill to split the nut. Then holding the stud with vise grips the nut spun off easily.