Mudflap screws nightmare

Hi guys n gals,
I have a dead parking sensor on my facelift freelander. I managed to remove the small plastic wheel arch flares, but the next step, removing the mud guards is proving very difficult. The screws are rusted in solid, and my drill is not able to drill them out, New drill bits used 5mm and 3.5mm just not cutting , even with cutting fluid. Is there a handy tip to remove these things? Sees this 10 year old truck is far more rusty than my 25 year year old Alfas.
- Frustrated of Cambridge.

I've cut a straight slot into the head of the screw before with my dremel and a cut-off wheel. Enables you to get a flathead screwdriver in there far enough that it won't slip.

freebiker said:

I've cut a straight slot into the head of the screw before with my dremel and a cut-off wheel. Enables you to get a flathead screwdriver in there far enough that it won't slip.

Click to expand...

had to do the same and also used an impact screwdriver , but funny enough a 18 volt cordless drill with a screwdriver bit and the clutch set low managed to slowly get them out

then bought some replacement stainless steel screws

OOoo clutch set low - hadn't thought of that. I will get the cordless on the side I haven't started to drill out (They have a few days of wd40 on them, didn't do much), and straight to dremmel on the other side. I would normally use the plumber's torch on stubborn screws, but in this case all the plastic would just melt away...I'm seriously considering just drilling out the duff parking sensor so I don't have to remove the bumper. I've had bad experiences using stainless bolts in the past, so I am a bit hesitant to do the replacement, but I think for trim like this it might be ideal.

Update: Of the 8 screws tried so far I have removed 2 using an 18v drill with a screwdriver attachement - I found you need low torgque setting, high speed then press trigger quickly. It seems the impact is what loosens some of them. 2 have been removed using the "dremel-like" cut off disc, which has eaten four discs so far. I'm exhausted now, having a tea break while I reload the dremel discs. I feel very Canadian today, working on my 4x4 in the snow, using a hockey puck under the jack cup. At this rate I might even get the rear bumper off today...-Hazel

quick squirt of PlusGas, 30 mins tea break and try again. Sorted rusty screws on my 42 yo MGB.

Yes, plus gas is great if you can get it to the rusty bit, but it was all hidden away behing plastic bumpers and splash guards and stuff.

Success! a few broken nails, and my hands are cut to ribbons, but I now have parking sensors. It turns out the harness in the bumper had chafed on the bumper armature, the wire inside was quite corroded and black, had to cut way back to find copper colour which indicates it had been broken for some time. Hmm the seller told me the parking sensors were working too. How dishonest!
Now to find some replacement screws to refit the mud guards. :clap2:
Since landy has been so good, he'll get some new tyres now!

-Hazel