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4 upper shock bolts broken off in body!!! (of the Jeep)


 
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Gearhead41987
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Joined: 07 Apr 2008

PostPosted: Fri Apr 25, 2008 4:46 am    Post subject: 4 upper shock bolts broken off in body!!! (of the Jeep) Reply with quote

I just started installing new shocks in my 96 XJ (then one that I just had the motor replaced in after it grenaded). A simple task, that I have done on MANY vehicles over the years. Or so I thought. The front went on fine, and the new skyjackers looked great. Now for the rear, when I was removing the upper bolts, they all snapped off in the body... And now I'm stuck with no rear shocks, and a horrible drive in to work today.

I'm not sure how to go about repairing this problem...

Idea 1.
Make a steel plate, about 5x4 inches, cut out for the head of the shock in the center, drill holes out, weld the appropriate nuts to the backside to match the shock mount, the drill the old nuts out of the body, big enough that the new ones that are on the plate would take their place, then weld the plate to the body...

Idea 2.
Drill out the center of the old nuts that are welded in, and tap them out with thread tap for a slightly larger bolt.

I need some help here...
ANY suggestions would be appreciated!!!
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whlstnd
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Joined: 08 Feb 2007
Location: spfld,il

PostPosted: Fri Apr 25, 2008 5:14 am    Post subject: Reply with quote

when mine broke i used a air hammer and drove them out. bought new nuts and bolts. used open end wrench and a little tape to hold the nut in the access openning then incerted the bolt from the bottom and tightened it all down.
mike
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Orangeamc13
Got Rev Limiter?
Got Rev Limiter?


Joined: 20 Feb 2006
Location: East Springfield, Massachusetts - U.S.A.

PostPosted: Fri Apr 25, 2008 8:25 am    Post subject: Reply with quote

http://jeephorizons.com/tech/xjshock.html
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Gearhead41987
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Joined: 07 Apr 2008

PostPosted: Fri Apr 25, 2008 10:59 am    Post subject: Reply with quote

Orangeamc13 wrote:
http://jeephorizons.com/tech/xjshock.html


Awesome! I had started to lean that direction. That's definetly the way to go. Going to do it tomorow. (If I survive the drive home... lol)
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jppilot61
Moderator
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Joined: 06 Mar 2004
Location: Tappahannock, VA

PostPosted: Fri Apr 25, 2008 1:23 pm    Post subject: Reply with quote

Won't make you feel any better but this is very common on XJ's (Mine included)

If you are not successful drilling and tapping see this thread too:

http://tinyurl.com/69se8f
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1992 XJ Laredo
RE6130 4.5" XJ Super-Flex Kit
RE1801 Slip Yoke Eliminator Kit NP231
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