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Thread: 06 Tj rear passenger top shock bolts snapped!

  1. #1
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    06 Tj rear passenger top shock bolts snapped!

    a little background on the jeep. hardly driven 100 thou kms on her..

    we were doing a 2.5 suspension lift and the when it came to every part on the vehicle it was easy to work with.

    to say that least our luck ran out when i encountered the rear passenger top shock mount bolts. 13mm The bolts ended up snapping when i was trying to wiggle them loose.

    its now dark out so i coulnt get a picture, but the heads sheard off. the stud is still in the upper brace.

    what ive tried:

    -because the jeep also has a small body lift i attempted to stick a pair of vice grips on top of the stud but that didnt work they just kept slipping off.
    -i tried drilling them through so i could potentially use and "EZ out" but after several broken drill bits and only about 1/16 of an inch drilled i gave up after dark.

    right now ive literally drenched them in a special crane penetrating grease so hopefully they loosen over night.

    what im hopefully going to try tomorrow:

    going to heat them up with a torch (propane)(all i have) and see if i can rock them loose with the set of vice grips from the top.


    any suggestions would be great guys thanks in advanced.

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    06 Tj rear passenger top shock bolts snapped!

    Don't use heat (flame) as gas tank is there ... I would get a colbalt drill bit... And keep drilling it ..... Anyone know the size of bolts tho? As I need soome lol


    OF4WD #7796

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    if the setup is anything like the XJ (there's space above the welded nut and "some" form of access) punch thru the welded nut and use a wire or mechanics wire to pull thru new bolts/washer from the top side. Then nut from the bottom rather than vice-versa...on the XJ i had enough room to hold the bolt with a wrench

    i just went thru this myself on the XJ:
    originally bolted from bottom, but once they all snapped off i was left with this. punched the broken bolts then taped the bolt to some 12ga wire and pull them thru

    actually, if you have enough room to access the top of the bolt with v-grips you could still run bolt up

    i'd try the cobalt drills first tho if you can save the threads, this is kind of a last resort save

    Last edited by Whiplash; 04-15-2014 at 06:13 AM.
    '99 XJ Sport - Black - BUILD THREAD
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    06 Tj rear passenger top shock bolts snapped!

    ...

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    I replaced the shocks on my 05 LJ yesterday. Its a little late to be telling you now, but I have been soaking those upper bolts with PB Blaster for the past 3 weeks. They all came out, but I had to be VERY careful!

    Sorry about your luck.
    Wounds heal... Chicks dig scars...

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    Thanks for the replies..
    @whiplash
    You were able to just hammer the bolt trough the threads ?
    How hard were you hitting them ?
    Did you bent the crossmember ?

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    Rotate 90 and re-drill 2 new holes? I did that.

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    06 Tj rear passenger top shock bolts snapped!

    I swapped out my 99s last year. I just put the heat to them with a propane torch spun right out
    WARNING! I am about to do something really fawking STUPID!!!!!!
    ᄅ# pɐǝɹʇǝɹ
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    The ones on my 99 were beyond saving so I had to cut access holes in my floor to get to the top and ground the tops off. I then put new bolts in and tacked them to the cross member to make life a little easier. Its not ideal but its all I had left
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    my bolt heads snapped clean off .....drilled and tapped new holes ,had to use an extension on my tap handle though ....good luck
    OF4WD member 7468

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    Quote Originally Posted by Quantum_shell View Post
    The ones on my 99 were beyond saving so I had to cut access holes in my floor to get to the top and ground the tops off. I then put new bolts in and tacked them to the cross member to make life a little easier. Its not ideal but its all I had left
    I did the same thing makes life easier in the future.

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    no, i hammered out both the remaining bolt AND the welded nut...left me with just an open hole
    used an air hammer. It's not really a cross-member on the XJ, more an added floor support?? but no damage to it whatsoever

    i also had to remove a shackle bolt that had no access to replace a nut, i drilled it out with a few different sized bits until i was able to work it out.
    i couldn't find any over the weekend but something i would have tried first is leftie bits on a reversible drill...drill a pilot and possible the next size up bit will grab and back the bolt out

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    Quote Originally Posted by hustler View Post
    rotate 90 and re-drill 2 new holes? I did that.
    genius!!! (wish I did that when I swapped shocks on a TJ years ago.)

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    06 Tj rear passenger top shock bolts snapped!

    What size of bolts did you use?


    OF4WD #7796

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    Me?

    Dunno, I grab a whole bunch of Grade 8 miscellaneous nuts, bolts, washers when I'm at a bigger TSC and keep them in sorted bins at home. I just put something close to stock size in and tightened it up.

    Grade 8 stuff seems to hold up to rust better, even if the strength isn't needed. And, knowing that any bolt you have replaced on your Jeep is Grade 8 means you have good interchangeability in a pinch should something else break.

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    06 Tj rear passenger top shock bolts snapped!

    Lmao I don't do that .. Lol


    OF4WD #7796

  17. #17
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    Ok guys figured it out.. I ended up getting a Dremel in there and cut the weld holding the nuts on. In there place I grabbed a could 5/16 x 1.25 bolts and shes all set now .
    Thanks for all the sugestions.

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