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Unread 08-21-2013, 08:54 AM   #31
Merc1973
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Quote:
Originally Posted by D0dgeRam1500 View Post
I'm all SAE now.
You re-tapped the rear axle housing for SAE threads?

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Unread 08-21-2013, 10:45 AM   #32
D0dgeRam1500
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Quote:
Originally Posted by Merc1973 View Post
You re-tapped the rear axle housing for SAE threads?
Yes, I overhauled everything underneath. It was a ***** but whoever buys my Jeep will thank me.
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Unread 08-21-2013, 11:26 AM   #33
Merc1973
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Quote:
Originally Posted by D0dgeRam1500 View Post
Yes, I overhauled everything underneath. It was a ***** but whoever buys my Jeep will thank me.
Nice work!!!!
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2002 WJ Ltd. 4.7 V8, QuadraDrive
1973 Mercury Cougar Xr7 convertible 351CJ, C6, 9" rear
1970 Kaiser-Jeep M35A2 W/OW 6x6 Multifuel D-Turbo.


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Unread 08-22-2013, 05:51 AM   #34
Tollmtn
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Quote:
Originally Posted by tinman77 View Post
Got it! So what I did tonight was drill a small hole next to the broken easy out and drove a nail in the hole. From there I took a hammer and prison shank and tapped the broken bolt in both directions until it finally turned. So long story short I was able to get out the last two bolts. Cleaned up the threads and installed the factory class10.9 bolts and torqued them to 120ftlbs to test my handy work. Your numbers are right on the money! The supplied bolts are only 75mm. The broken pieces are a 1/2" long. I ordered some 80mm long bolts from fastenall and now I'm second guessing my self I think I'm going to order some 100mm bolts tomorrow just to be safe. The threads on two of the three holes are not the cleanest due to my drilling ability and the broken cast so i it's probably safe to say the 100mm bolts are the route to take.
Good going, metal is a stubborn material to work with and at times you have to be just as stubborn if you want to complete a job. And... Yes I agree, if there is enough thread depth 100MM would be the way to go. I certainly wouldn't go less than 90mm with a 2" spacer.

Threads can look pretty ugly, have some of the crest shaved off, be kind of dinged up looking in general and not lose as much strength as one would think. If the damage gets down near pitch diameter that's another story. So being that it held at a good torque proof test for an aluminum casting you should be fine. Let us know how or if the 100mm bolts work for you.
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Unread 08-23-2013, 08:52 PM   #35
Marksikern
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Might want to run the same size tap downs those threads just to clean them up and make sure you have no bind or cross threads, probably pretty hard to see all the way down the bolt holes. That is what I would do with all the work you've already put into the job. I'd tap for the 100mm. Good luck.

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Unread 09-14-2013, 08:18 AM   #36
squire_wj
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I know this thread is a little old but mine just did the same thing today on me.
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Unread 09-14-2013, 08:36 AM   #37
squire_wj
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What size bolt did you end up using and length?
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Unread 09-14-2013, 08:51 AM   #38
Tollmtn
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Quote:
Originally Posted by squire_wj View Post
I know this thread is a little old but mine just did the same thing today on me.
Details please, was it another 2" RC spacer with 75mm 8.8 bolts? If so, I wonder if anyone has informed RC that the bolts are not the correct length and they are a class lower than they should be?
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Unread 09-14-2013, 08:52 AM   #39
squire_wj
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Yes it is the RC 2inch spacer, I am not a 100% sure on the length. I am not very impressed that I have to pull the rear end off the jeep.
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Unread 09-15-2013, 12:06 PM   #40
tinman77
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Hey guys sorry I did not notice the other post... I went with class 10.9 bolts 80mm long. Had to order them from fastenall. My advice is to go longer. You may not need to pull the rear diff. Pull the A frame link on top to access the bolts. There is enough room one that is out of the way. Also since you have the rear link off have a new all joint pressed in. I'm actually under my jeep today inspecting the bolts to make sure everything is still kosher
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Unread 09-15-2013, 12:08 PM   #41
tinman77
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One more thing I did get ahold of RC sent three e-mails and no response. I talked to their sales manager once and specifically told him the grade or class of bolt of is too light and too short. I was Hoping for some sort of response through e-mail maybe ill try again on Monday
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Unread 09-15-2013, 04:15 PM   #42
Tollmtn
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Quote:
Originally Posted by squire_wj View Post
Yes it is the RC 2inch spacer, I am not a 100% sure on the length. I am not very impressed that I have to pull the rear end off the jeep.
I would not be impressed either. Now you know that 75 mm class 8.8 bolts will fail. 80 mm 10.9 bolts are stronger but 5mm only gains you 2.5 threads so they are still are well short of the depth that the OEM bolts screwed in.

So IMO you are living dangerously with bolts shorter than 90mm. 90mm bolts with a flat washer will screw in to OEM depth plus one half turn.

OEM flange bolts with just the ball joint go in to a depth of 1.200"

80 mm bolts with flat washer and 2" spacer and the ball joint go in to a depth of .855"

90 mm bolts with flat washer and 2" spacer and the ball joint go in to a depth of 1.249"

I checked the depth of one hole (the drivers side front) to see if a 100mm bolt would work with a 2" spacer. On my diff it would not it, it got tight like the hole was not tapped deep enough or it bottomed out a good 1/16" before it the bolt was down against the spacer. I did not check the other two holes seeing that the only way 100 mm looked like it would work is if you used extra flat washers.
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Unread 09-15-2013, 04:47 PM   #43
squire_wj
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So if I get a 90mm class 10.9 bolt with a washer is should be good. I am going to bring the broken bolt with me to the bolt store and make sure I get the right size.
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Unread 09-15-2013, 07:31 PM   #44
tinman77
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Yes definitely go with the 90mm I'm going to order some on Monday and replace the 80's that I have in now. Take some pics and post em so we can keep this thread full of info for anyone else that may end up having the same problem. Maybe if we get enough people with this problem we can actually get a response out of RC! Like I told their sales manager over the phone I was not looking for anything out of them just acknowledgement of the problem and action to solve the issues with their kit. If I were you I'd call them and see what they say.
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Unread 09-16-2013, 04:37 AM   #45
squire_wj
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I plan on taking pictures and will upload them when I do. In my opinion this is unacceptable, if that had broken at highway speeds it migh have cased me to go off the road or really hurt someone.
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