Hello all, hope all is well! I Have not had time to work on p38 since COVID Hit. My 1996 RR 4.0 se is now running (See Photo). My latest task is trying to remove the Brush Guard and front bumper. I reviewed RAVE and related threads. Most say Remove 2 bolts underneath (Inside Crush Cans). One of the bolt heads is sheared off and the other is rusted solid and I'm sure will break off when I apply pressure. I also read Once the other bolt head breaks off, flip the clips on each end, push down on the bumper and slide it off. I also read to Then drill out the rusted bolt studs out of crush cans. The bumper won't budge at all. Questions: How do I get/stand-on the front bumper to go down enough to clear crush cans to slide the bumper off;
What type of drill bit is best to drill the bolt studs out of the crush cans?
Thanks,
Jesse

Since you are going to drill out those bolts you might as well do that and then you will be able to slide out the bumper. Go to a proper tool store and buy some quality high speed steel drill bits. No Wal-Mart junk. You probably need 1/8, 5/16 and then one large enough to get out all of the bolt, maybe 3/8 or 7/16. Then get new crush cans unless you can weld in new nuts to replace the drilled out ones. Wear safety glasses as a minimum when lying under the bumper drilling. Might be a good idea to use a hammer and center punch the center of the bolts so that you drill through the center as much as possible.

Anyone that owns a P38 should periodically take those bolts out and coat them with anti-seize grease. That is preventative maintenance.

Gord Wedman said:

Since you are going to drill out those bolts you might as well do that and then you will be able to slide out the bumper. Go to a proper tool store and buy some quality high speed steel drill bits. No Wal-Mart junk. You probably need 1/8, 5/16 and then one large enough to get out all of the bolt, maybe 3/8 or 7/16. Then get new crush cans unless you can weld in new nuts to replace the drilled out ones. Wear safety glasses as a minimum when lying under the bumper drilling. Might be a good idea to use a hammer and center punch the center of the bolts so that you drill through the center as much as possible.

Anyone that owns a P38 should periodically take those bolts out and coat them with anti-seize grease. That is preventative maintenance.

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Hey thanks for responding! Drilling from the floor looking up while metal is falling is not my preferred 1st option. Is there any other way to remove bumper 1st then drill out bolts? Same question for brush guard?
Thanks

I can appreciate your hesitation. A face shield would be better than glasses. Wear covers and tape at the wrists. Gloves of course. I don't know if you can pull out the crush cans with bumper attached. You can't get the bumper out of the cans as long as those bolts are in there.

When you knock it out dont forget to disconnect your fog lights