Control Arm woes
 

I removed the LT & RT front tension strut to replace the bushings and ball joint. The issue is that the torx bolt on the inboard side sheared it's head off and I cand get the dang thing out of the carrier's (Knuckle). Any idea's besides total dis-assembly of the front end to remove the carrier to drill them out? TIA

The head is completely gone? I would say you'd have to drill it out then

If head is completely gone, then drill out is the only option.
Or get new knuckle.

If you are going to have to drill it out, first hit the threaded part on top with some PB Blaster or Kroil penetrating fluid. Then go out and find a left handed drill bit and extracter of the right size (bolt is a M10X1,5X20-10.9). Drilling won't be easy as this is a grade 10.9 bolt. P/N 31106766780

I have a Mac tools set of left handed drill bits and extractors and they work like a charm, every time. Don't cheap out here (though I got my set on ebay).

Go with a slow drill speed, strong pressure, a steady hand, and lots of penetrating oil as lubricant/heat transfer fluid.

What worries me the most is that even if you are able to drill out e-torx bolt, you will have tough time removing ball joint itself from knuckle.

If e-torx is rusty enough to sheared it's head off, most likely ball joint is bonded to knuckle as well.

This is like simple DIY job ended up with nightmare. If you are handy, have all necessary tools, and most importantly patience, then try drilling it out. Otherwise, take it to shop if possible.

If you fail on drilling it out, then knuckle + wheel bearing + mine as well new CV boot.

Best of luck man!

Right? I thought that this was an easy job when I started it! It has been challenging. trying to figure out how to get the ball joint out of the knuckle is going to be interessting. I'll tell everyone this though, I am anti seazing everything as it goes back together.

As White 46 noted my simple DIY turned into a PITA. I never did remove the 10mm Torx 10.9 bolts. I said to hell with it and drilled them out and up to 7/16" installed Grade 8 bolts because finding Metric 10.9 bolts were I live is close to impossible. Ok, Driver side done, Cool. Next passneger side, gonna be easy right? Oh yeah! NO! My outer spline to the half shaft would not budge. I wound up removing the Knuckle with the half shaft, putting the combo in my 20 ton Vice and pressing the damn thing out, and it took every bit of that press to do it! When she let loose it sounded like gunfire, scared the hell outta me. So now, I drilled out the other knuckle, grade 8 installed, and now rebuilding my Half shaft. Wow, what a journey so far.

If you don't have a ball joint tool and not that cucumber fork as Mrs. Upallnight like to call it, that is your problem. I replaced ball joints on my E34 BMW and just yesterday on my new to me G35 Infiniti and used a ball joint tool to pop it off. If you never did a repair, go to Youtube and watch a video on the Proper Procedures to use. You can rent tools for free in some case from auto parts stores. I rented a ball joint removal tool from Advance Auto for free and pop that ball joint out of the knuckle.

No ball joints were hurt or killed in this episode of BMW X5 destruction/repair. :D