Ran into some trouble while changing struts

[azncapcom]

First i spent hours trying to get the seized rusted nuts off at the front. After i finally replaced the front... I went to the rear of course...

The rear were just as rusted as the front... however the rear i had to remove the sway bar link... which requires using an allen key on the inside and wrench on outside... well you guessed it... it was so rusted, the allen key hole stripped instantly.

Now what are my options? How would i get this nut off? The worst case scenario that i can think of is just sawing the sway bar link off and replacing it with a new one...

are there any other options first?

[pdq]

Get a hacksaw and saw the bolt off. Or use a grinder if you have one.

If the link is so old you can't remove it, I bet it's junk anyway.

Use some PB blaster on the strut mount bolts, and make sure to use a 6-sided socket with a long breaker bar to get enough leverage to get them broken loose.

[Buurin]

Drill out the stud from what is left of the allen key hole. Then either bang or twist the nut off. Use a drill bit set designed for drilling metals. Did that with one of my front sway bar link. Get the replacement before starting.

[Bitter]

replace the bar bushings as well.

[azncapcom]

Ok, after sawing off the sway bar link... i still couldnt get the bolt out... there was still a piece that acts like a washer on the screw opposite side of the nut...

I then tried using a nut splitter... and that didnt work and just chipped the splitter itself...

Then the last resort was using a metal grinder.... had to shave off a tiny bit of my sway bar to fully get the screw out....

Spent 6 hours on it last night on the rears.... oh well at least its over now.

[gold94corolla]

Same thing happened to me... except the links were stuck to the struts I was removing. So I just got new links to go with the new struts, worked fine.