TD5 - Outrigger bolts and side steps?

I am trying to put sidesteps on my 1999 Disco TD5 (for passengers suffering with arthritis). I have managed to remove the nuts from 3 out of the 4 outrigger bolts in order to attach the steps (Bearmach rubber coated if of any interest).

I have regularly soaked the bolts in WD40 over the past week and with a little persuasion got the first three off.

However, ehe 4th little sh**e (offside rear) won't release at all and I have now rounded off the bolt head above the outrigger... oops!

Firstly, any suggestions on how I can get this nut to release as even clamping the upper bolt head with molegrips is just continuing to round off the head.

Secondly, there doesn't appear to be much space above the bolt but could I replace it easily if I resort to the good old hacksaw to get the old bolt out?

As a desk jockey my ability to use tools is a little limited and any help would be greatly appreciated as the car looks a little odd with a sidestep on one side and not even a mudflap on the other...

On the plus side it is the passenger side which was successful so not getting as much grief from the wife and kids .

you will have to cut it off and replace by either drilling hole above thru floor or put back in from bottom up

Hi James(?)Martin,

Thanks for the prompt response... don't fancy drilling through the floor (a bit drastic) so will have to look at putting bolt in upside down as you suggest. What is the bolt size / thread size? Can I get a bog standard bolt from a hardware store or does it need to be of a specific type or metal? I'll make sure I put a locking nut on the top too... Spring washers or what is best...?

Sorry for all the picky questions but want to get it right first time and not shaft myself by not having the parts when I do it.

m10 x 92 std 8.8 will be fine use nyloc

JamesMartin,

You're a star... thanks for the help... hope I can be of assistance in return one day.

Don't drill a hole through the floor and you don't have to put the new bolt in upside down, the rubber bushes on the outrigger are split top and bottom once you have the old bolt out prize the top rubber bush off, put the bush on the new bolt and it will (at an angle) go back in, from the top. Oh and :welcome2:

Thanks Oldskool... I'll give it a go at the weekend. And thanks for the welcome even though I've been on here since before Xmas...

For the record... B&Q wanted over £8 for five bolts... Guy Salmon Landrover want £1.20 each for the proper part... I only need the 1 bolt so a bit of a no-brainer .