Broken head on 7mm door panel screw

[filipradenovic]

I was replacing weatherstrip inside the passenger door in my 2018 Mustang Convertible, as the original one got deformed and it was scratching my window. Everything went smooth, removing the door panel, removing weatherstrip, installing new one, putting back 2 x 10mm screws in the top, and then ... one of the bottom 7mm screws head broke while I was tightening it.

I ordered new screws, but does anybody have a tip on how to remove the leftover screw part that is screwed inside the door without making even more damage?

The thing is, there is no vibration or rattling of the door panel, I think plastic clips and 3 leftover screws are holding the door just fine, but I would like to fix this if I can. It bothers me that I broke it.

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[Bitten in '69]

Use a small left-handed drill bit, on low speed. Be sure to center-punch the broken screw. The low speed will allow you better control. Hopefully, working with the reverse bit, when it grabs, it may turn the screw out for you.

 

[ORRadtech]

If there's any of the screw shaft sitting above the door it can sometimes be grabbed with a pair of locking pliers (vice grips) and turned back out. Another option might be to use a dremel with a cut off wheel to cut a slot in the screw to use a flathead screwdriver on. Drilling is tricky, you need to start, and keep going, dead center. A reverse bit may back it out, a forward bit may push it through. I've had it work both ways.
However you try, I'd have touch-up paint on hand.

 

[filipradenovic]

Thank you, will try the suggestions

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