I've got a 96 4Runner that I bought new - it's spent its entire life in the rust belt (upstate NY). Some bolts are getting to the point where they are pretty well rusted. I was trying to remove my gas tank skid the other day with a 3/8" drive ratchet/socket and, even with PB Blaster, I broke off 2 of the bolt heads.

Would air/impact tools make any difference? Or are rusted bolts rusted bolts, and there's not much I can do about it besides a torch or PB Blaster?

 

Impact will just break them faster usually (ask me how I know ). BUT - PB Blaster should help - needs to soak in good to be effective. Usually applied over several days will do the job. Heat usually works also to minimize breakage.

 

Sometimes impacts can help break a rusted bolt loose or they can break them off faster as noted above. The key is to turn the tool torque down and work up slowly using the impacts to do the work. And sometimes you can alternate between tightening and loosening to help loosen the fastener. A good penetrating oil, like PB Blaster, given time to work is the best bet and a propane torch to heat things up (if possible) helps too. And be sure to use anti-sieze on all the fasteners you put back in.

 

if there's a bolt i'm scared of breaking, i'll try it with a breaker bar and see if it gives. if it feels like it's going to snap, first i try the penetrating lube and giving it a smack with a hammer and a punch. if that fails, i put some heat on it. usually does the trick.