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Discussion Starter · #1 ·
Well darn. Trying to install the crossbars on the roof rack and every single one of the plastic placeholder screws sheared off at the head when I removed them. I thought they were buttons until I was unable to get the metal screws to go in. Does anyone know how to get them out?
 

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Use a prick punch and hammer to put a punch mark in the center of the broken screw. Get a drill that's a bit smaller than the smallest diameter of the screw and very carefully drill it out with a hand drill. That might loosen it up enough to use a phillips head screwdriver jammed into the opening to back it out. If not, then try using a pick or small screwdriver to break out the remaining threads.
 

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Use a prick punch and hammer to put a punch mark in the center of the broken screw. Get a drill that's a bit smaller than the smallest diameter of the screw and very carefully drill it out with a hand drill. That might loosen it up enough to use a phillips head screwdriver jammed into the opening to back it out. If not, then try using a pick or small screwdriver to break out the remaining threads.
And I actually have some left hand drill bits for doing this kind of stuff - they work really well using this technique and save a lot of effort.
 

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Discussion Starter · #4 ·
Use a prick punch and hammer to put a punch mark in the center of the broken screw. Get a drill that's a bit smaller than the smallest diameter of the screw and very carefully drill it out with a hand drill. That might loosen it up enough to use a phillips head screwdriver jammed into the opening to back it out. If not, then try using a pick or small screwdriver to break out the remaining threads.
Thank you so much. The dealership offered to replace the plastic screws with more plastic screws for a mere $180. They didn't understand what I was trying to do. (Car left for recall service and I figured I'd ask)
 

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Drill out the center of the broken screw, as Matt suggests above. Use a bit about 1/2 the diameter of the screw. Then use a screw extractor to back out the threads. This tool has a left hand tapered twist. Tap it into the drilled hole and turn it back out. Harbor freight should have them.
 

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I'd go with a set of LH drills if you need to buy something - I've had more success with those than regular screw extractors. Not saying the extractors don't work, just that LH drills work really well :)
 

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Discussion Starter · #7 ·
Thanks guys! I turned it over to husband and he did as you suggested. Roof rack installed! Come on, Honda...spend the extra 3 cents and use metal screws instead of creating a problem for people.
 

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2019 Pilot EX-L AWD, 265-60-18 Defender LTX M/S
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Consider some never seize version on the screws you installed in case you ever want to remove them for some reason before they rust/corrode in there.
 
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