Good news and bad news. First, the good.
I got the new body mount bushings, bolts, and washers replaced. I did all of them except the front one and the driver's side rear which will require I open up the sheet metal and probably re-weld the captured nut.
As usual, I took some photos along the way.
I had already loosened up all of the bolts so that part was out of the way. The mounts in front of the rear wheels were the rustiest. The mid and forward ones weren't too bad.
Here's the rust, dirt, and debris that came off the aforementioned mount in front of the driver's side rear wheel:
After you get all of the bolts out on one side (and I loosened the bolts on the other side a couple of turns), you jack up that side of the tub. Here's my rig:
(it almost looks like the 2x4 is on the aluminum trim piece, but it's actually on the bottom side of the tub)
Here's the mount with the tub partially lifted up:
Here, I've hacked at it with a screwdriver and hammer, and lifted the tub a bit higher. At this point I'm not understanding that I need to get the tub about 3" high to get enough to do the work right.
Finally, I get the old debris out. The trick I finally figured out was to hit the bottom of the old bushing with a hammer to push it up and out.
I used a small stainless steel brush (picked it up at the gun show for a buck) on the 4 mounts with rust. I cleaned them off then dabbed on some rust converter before installing the new bushings.
(One word of warning: Don't trust your health to a low-end Chinese-made jack, or any jack for that matter. While the tub is lifted, take the time to block it or brace it with some static supports that will prevent the tub from crashing down on your hand if the jack fails)
Here we see the new bushing in place, along with some un-cured rust converter:
If you've never done this before, this image and the previous image will be very helpful. They show you exactly how the parts fit together before they're tightened down.
The bushing with its imbedded metal collar sits in the top, and the other poly piece sticks on from the bottom. Then a bolt with washer sticks up into the captured nut in the tub to hold it all together:
It was pretty weird seeing the tub sit at an angle:
Here's the little stainless steep brush I used to knock off some rust. It's like a tooth brush:
Here's the rear passenger-side bushing hole after some clean up. It had some rust around it.
Here are most of the parts I removed. Some of them were not too bad. Others were severely worn. I had to burn out 2 bushings with a torch, and let me tell you.. that makes a huge mess. The melted/burned rubber turns into a tar substance that its difficult to remove from tools, skin, the garage floor, etc.
Like many Jeep projects, once you deal with a few of these then you start to work more efficiently. After doing one side, I was able to do the other side a bit faster. If I had to do it all again I would have a better appreciation for the hurdles and potential problems.
Some of the most worn pieces:
There was a question about where the larger (in height) bushings go. The installation directions (below) have them in position #3, however my CJ had the old ones in position #2. More specifically, my CJ only had one large bushing (driver's side). The passenger side #2 looked like all of the others.
To be honest, I don't know why there are different size bushings for position #2 (or #3). There is probably a good reason but it's lost on me.
As far as bolt sizes, the details in my earlier post about bolt sizes
seemed to work out fine (although I didn't try the new bolt in the front mount yet)
Oh, the bad news: The new bushings didn't fix the creaking sound I hear when the frame flexes. I spent 15 minutes to lower the transmission mount/cross member about 1/4 inch, apply lithium grease between that and the frame, and re-tighten the 6 bolts. My theory was the crossmember was creaking. No luck. That didn't change a thing.
At least I have new body mounts though. I still need to do the front one under the radiator and the rear/driver's side one, but it's been a long, long weekend so I'm done for now.