Lost Hitch Bolt/Washer Inside Frame

[RandallOfLegend]

When pushing the hitch up into place I didn't leave the fish wires on the bolts and managed to push one of the bolts back into the frame rail. It looks like the only way to get it out now is via removing the bumper to access the end of the square channel. Or I bolt it in place with only 3 bolts and have something rattling around.

Thoughts? It's for a bike rack not for towing (not rated in the US). Either way, thoughts? (aside from how stupid I was to leave the fish wires off)

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[Garbone]

The tip up and shake until it falls out is probably a non started.

 

[Ford_orr]

When pushing the hitch up into place I didn't leave the fish wires on the bolts and managed to push one of the bolts back into the frame rail. It looks like the only way to get it out now is via removing the bumper to access the end of the square channel. Or I bolt it in place with only 3 bolts and have something rattling around.

Thoughts? It's for a bike rack not for towing (not rated in the US). Either way, thoughts? (aside from how stupid I was to leave the fish wires off)

Not sure about the lost bolt, but I would NOT mount the hitch w/only 3 bolts. That solo bolt on one side is gonna shear off if you hit some bumps or dips w/a heavy load on the hitch. Even if you only put a cpl of reg bikes on it, there are still stresses going throughout the hitch mount. It's been designed the way it is with four bolts for a reason (I believe it's even six bolts in the EU).

 

[DrMaine]

Can you use a bendable magnetic retrieval tool to fish it out?

 

[rhougey]

When pushing the hitch up into place I didn't leave the fish wires on the bolts and managed to push one of the bolts back into the frame rail. It looks like the only way to get it out now is via removing the bumper to access the end of the square channel. Or I bolt it in place with only 3 bolts and have something rattling around.

Thoughts? It's for a bike rack not for towing (not rated in the US). Either way, thoughts? (aside from how stupid I was to leave the fish wires off)

I would go after that bolt. Any way you could apply compressed air into one end of the square channel and blow it out the other end, or push it out with vinyl tubing from one end (flexible but also stiff), or stuff a magnet into the end of the vinyl tubing to try to grab it with the magnet? Don’t know how much access to to open end of the channel you have.

 

[RandallOfLegend]

So I ended up doing the "right" thing. I did a 90% removal of the rear bumper. There is a beefy harness connection on the driver side I left free. I just dropped the bumper shell onto a foot stool.

Youtube Video for Bumper Shell removal


Here is the mess

Frame bolt loose in the channel

Final Results (Curt Trailer Hitch Receiver - Custom Fit - Class III - 2")

So I learned a lot. Not something I wanted to learn. Keep the fish wires on your hitch bolts until all 4 are aligned and you're about to finger tighten a bolt on. This is my 4th hitch install, and the first time I removed the fish wires early to "make it easier". The bumper shell removal wasn't as terrible as I was expecting. But you had to be careful to not scratch the paint or tug on any of the sensor/lighting wires.

 

[rhougey]

So I ended up doing the "right" thing. I did a 90% removal of the rear bumper. There is a beefy harness connection on the driver side I left free. I just dropped the bumper shell onto a foot stool.

Youtube Video for Bumper Shell removal


Here is the mess

Frame bolt loose in the channel

Final Results (Curt Trailer Hitch Receiver - Custom Fit - Class III - 2")

So I learned a lot. Not something I wanted to learn. Keep the fish wires on your hitch bolts until all 4 are aligned and you're about to finger tighten a bolt on. This is my 4th hitch install, and the first time I removed the fish wires early to "make it easier". The bumper shell removal wasn't as terrible as I was expecting. But you had to be careful to not scratch the paint or tug on any of the sensor/lighting wires.

Good job. Happy cycling!

 

[Nikos]

When pushing the hitch up into place I didn't leave the fish wires on the bolts and managed to push one of the bolts back into the frame rail. It looks like the only way to get it out now is via removing the bumper to access the end of the square channel. Or I bolt it in place with only 3 bolts and have something rattling around.

Thoughts? It's for a bike rack not for towing (not rated in the US). Either way, thoughts? (aside from how stupid I was to leave the fish wires off)

Use a magnet, quite strong one. Run the magnet along the rail and move it close to the hole you want to place it.
You are not the only one who has lost a bolt inside the frame rail.

 

[Stephen Munro]

Not sure about the lost bolt, but I would NOT mount the hitch w/only 3 bolts. That solo bolt on one side is gonna shear off if you hit some bumps or dips w/a heavy load on the hitch. Even if you only put a cpl of reg bikes on it, there are still stresses going throughout the hitch mount. It's been designed the way it is with four bolts for a reason (I believe it's even six bolts in the EU).

I concur with the advice on bolt count. The Torklift hitch I installed on my MME is fastened to the frame with 6 bolts, 2 oriented vertically into each frame rail and 2 oriented horizontally into the rear cross member. I would suggest a minimum of 4 bolts, with 2 in each axis, for the best shear resistance.

 

[whitelightning99]

Years ago, 1985 specifically, I had a persistent rattle on the driver's floorboard during acceleration or braking. It actually turned out to be a bolt left by a "Friday" Ford assembler in the frame rail. Had to drill a hole in the hollow rail and used a magnet to retrieve ir.

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