Crossmember bolts stripped -
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Unread 09-26-2002, 12:06 AM   #1
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Join Date: Jul 2002
Posts: 28
Crossmember bolts stripped

Something's been making a fair amount of noise in my clutch, and it's about time to change it out anyway, so I was going to try to drop the tranny last weekend.

But when trying to get the crossmember off, I ended up stripping a few of the bolts. It's been years since they've come off, so I'm sure they're completely rusted out.

They were extremely stiff, but only a few came out. 2 stripped and I broke the head off another. I was trying to do it as gently as possible, but now I'm afraid I'm screwed.

How do you suppose I get 'em out, and what should I do about re-tapping and replacement?

-=Jeff Merkel=-
'88 YJ 4.2L
Weber 32/36, Mallory Ignition, Owned since '93.
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Unread 09-26-2002, 11:11 AM   #2
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Join Date: Sep 2002
Location: Northern CT
Posts: 1
Jeff, I think this is very common with old Jeeps. If the welded in nuts are still solid just get some sharp bits and drill them out and re-tap. For me, I was lucky, I was able to knock out the welded in nuts. I then made steel plates with studs sticking out of them. Loctite (permanent stuff) the studs into the plates. Then I slipped the plate/stud assemblies (I made 6, one for each hole) through a big stamped hole in the frame and somehow slipped each into position. Then I made small sheet metal retaining clips to keep the plate/studs from pushing through when you try to put in the crossmember. (you could use nuts to hold in the plate/stud, but the crossmember will then stand off from the frame. Anyway, I've also seen people use angle iron bolted to the sides of the frame. The horizontal part of the angle iron is in the same plane as the bottom of the frame. Make new holes in your crossmember and you can bolt it up.
Nothing is easy.

Squid, 81 CJ-7
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