Shock bolt replacement: a fix with pics (Heavy)

[XJ Xtreme]

OK, I have seen this problem posted on a number of forums and have seen a number of suggestions for the fix. While most, if not all, are valid, I thought that I would post my fix as it has worked well for me several times and is relatively simple.

My Buddy tried this: (Yikes)



I told him I had a better way.

First off, most Jeep owners will tell you that anytime you try to remove a the rear shock bolt, the dreaded snap is always in the back of their mind, so I will tell you in this procedure, we want the snap. We pray for the snap…in short, the snap is good.

First we backed the jeep up on ramps for room to work but you can use stands as well. Just make sure it is secured!

Tools used:
½” Breaker Bar
Ratchet & extension w/ ½ & 7/16’s heads
Impact gun (Air works best but electric may do the job)
(4) ¼ 20 X 3/4” bolts, washers and nylox nuts (optional as you can use Blue thread loc as well)
Telescoping pick up magnet

Step 1: We used a ½ breaker bar to snap the bolt heads. It didn’t take much.



Step 2: We removed the old shocks.



Step 3: We used a small air impact gun with a chisel bit to break the nuts free of the weld and removed them.





Step 4: Through the access hole we used a telescoping magnet to fish the new ¼-20 X ¾” bolts (with washer) down through the bolt hole. This can be a little tricky. The use of a small pick, needle nose pliers or tweezers are useful to guide it through.





Step 5: We then started a nylox nut and washer on a bolt one side and then mounted the shock on the bottom to give it some tension.

Step 6: We then used a 7/16ths open end to lock the top of the bolt from turning and a ratchet to tighten the nut and repeated this until done.

[IMG]http://i59.photobucket.com/albums/g289/XJXtreme/Shocks/S****s12.jpg[/IMG]



Total time, 45 minutes.

I hope this helps a few fellow XJ'ers out there.

OH....

My buddies Mall Crawler…hehehe

[ktmracer419]

be a man and cut holes in your floor with an angle grinder!

excellent write up!

I beleive this is Faq sticky worthy.

Make sure Balloo see's this.

[Meatroach]

well that certainly beat my drill & tap method! nice work!

Sticky x2

[BigBearXJ]

I use the drill and tap method. It probably takes around 45 mins also. Good idea though!

[PMAZ7]

Excellent documentation!

[tombob]

How do I access the "access hole" described below in Step #4? How difficult is it to remove the carpet in the rear without ripping it up?

"Through the access hole we used a telescoping magnet to fish the new ¼-20 X ¾” bolts (with washer) down through the bolt hole. This can be a little tricky. The use of a small pick, needle nose pliers or tweezers are useful to guide it through."

[BeachinXJ]

The access hole is on the underside almost right next to the bolt holes.. it is shown quite well in the pics.

[tombob]

Duh! Okay, thanks! Next time I will put on my glasses and look before I ask.

[parrothd]

Use a piece of saftey wire and fish it thru the hole and out the access port, then wrap the wire around the threads of the bolt and then use the wire to fish the new bolt into place..

They should make this a sticky, others here say to cut(rockfab.com?) the floor which I don't understand..

[UltimatE]

instead of the magnet thingy, you could use one of them long pieces of wire with threads on them. I have seen them but have no idea what they are called.

[ORJ]

Those bolts and nylock nuts are also available in stainless.

[XJ Xtreme]

I have seen this problem posted several times and responded with the above steps witthout pics, but I figured since I was doing it, I might as well document it.

Nothing spectacular but I hope it helps out.

Peace

[Steamer98]

... but the angle grinder is so much fun

Good write up, wish I had seen this a couple months ago.

[joe2feathers]

alittle easier idea once ya got the old bolt out ..just use a stick of tuff but flexi wire,,,masking tape ..feed in reverse ..pull bolt threw the hole undo tape

[98_classic]

Originally Posted by Steamer98

... but the angle grinder is so much fun

Good write up, wish I had seen this a couple months ago.

yea i went through my floors to. i tried everything i could to use a punch and knock the bolts out of there but ended up needing to go through the floor. looking back though it was fun and i got an excuse to go buy that much wanted angle grinder.