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Unread 05-03-2015, 09:11 PM   #1
McColorado
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1997 ZJ 
 
Join Date: May 2013
Posts: 16
Crossmember Drop / Reinforce

I just installed a 3.5" lift kit on my 94 Zj, and in the process of attempting to install the t-case drop, I have broken a cross member bolt, and one other just spins. Now, I could go and tear apart the interior in an attempt to gain access to these bolts, however, I have some experience welding, and have some scrap metal to work with. Here is my thought: use a 1" steel tube and some 3/16" plate to make myself a t-case drop bracket. I would weld and bolt the bracket to the frame, and bolt the cross member to the bracket using grade 8 hardware. All the joints between bracket and frame would be welded together. Here is my general idea:


So my question is: would this work? I'm just trying to find a way around the weak bolts, and thought this could be an effective solution. Any advice would be greatly appreciated!

The Jeep in question:


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Unread 05-08-2015, 03:52 AM   #2
bdmead01
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2000 TJ Wrangler 
 
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Your design seems solid, but I think the problem is with the crappy nutserts. You would think Jeep would have changed their design by now...
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Unread 05-08-2015, 07:03 PM   #3
underpowered
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to keep from crushing the uniframe and properly torque the bolts that appear as if they would go all the way through it, a small tube should be welded in place through the frame before the bolt is put through it.
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Unread 05-08-2015, 07:14 PM   #4
jason m
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A chunk of tube is needed as underpowered said to keep the sides from crushing. And if it were me I would run the 3/16 plate on both sides, yes this means it needs to get a bend in it, well really two but adding it on both sides ensures it won't go no ware.

Jason.
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Unread 05-08-2015, 08:00 PM   #5
JeeperDon
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Do it right. Just fix the bad nuts in the frame. Weld a nut on a small plate. Make a hole in the frame at the dead nuts (cut them out) just big enough to finesse the plate inside the frame, then weld the plate with the nut to the frame.
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Unread 05-10-2015, 11:19 PM   #6
McColorado
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Thought I'd throw a quick update on this -- Decided to just do it right. Got some grade 8 hardware on the passenger side with nuts welded to the inside of the frame, I welded the floor back in place, siliconed it to make sure it won't leak, and painted it to hopefully not have to deal with rust down the line.
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