Lift the body and remove the mount pieces and see if there is any bolt sticking below the body you can get on. Under the rear seat there is a square part of a raised panel that the mount is located under, you may have to go at it from the top to get it out. Ideally you will weld a nut on a piece of bolt sticking down and heat it up to twist it out.
If you want when you get it out pm me and I can send you the missing pieces I just did a bl on my jeep.
Since you don't want to cut the floor, and I don't blame you. If you don't own a set of easyouts I would seriously consider sending that to a mechanic and let them get it out with the drill. That's going to be such a pita there if your not tooled up for it.
bought the correct easy-out, bit, center punch and tried to get it out. no dice. 3/16" pilot hole went good, 19/64" easy-out hole went as far as I can...bottoming out the drill. hammered the easy-out in, but can't grip it with anything since the hole is so deep.
only thing i got left is drill all the way through with 7/16" bit and run a bolt through the floor
dremel cut a hole in the floor, rip the destroyed nutsert out, tack weld a Grade8 nut on the inside and try to reattach that way.
Can you put a nut up there and weld through the center of the nut to the bolt.
long past that point. the hole is at least 3" deep...no way to get the gun in there and ensure the wire goes into a nut. besides, the nut would have to be smaller than 7/16" in diameter...and i can't see torquing on an 8-32 or smaller with a 2 ft breaker bar.
i went to two mechanics. both said cut the tub and estimated around 3 hours labor ($100/hr). one guy was really helpful and basically talked me through the whole thing for DIY.
i bought some 0.024" wire & tips for my HH140...going to clean all the paint off the area, cut the tub with a dremel, grind the BS out and bore a new 7/16" hole, tack a Grade 5 nut in place and tack it all back together.
soooo....who's got an extra body mount laying around?
I know you don't want to Unlimited but I had this same body mount break off on me while doing my lift. The only way I could get it was to cut a hole in the floor. Although I sealed the hole up and covered it with carpet. If it makes you feel any better it is hidden under the rear seat assuming you still have one. Good luck with whatever you decide to do.
If you are going the "fix it yourself" route you can always utilize your down time to upgrade...
A buddys rig with the swag mounts. (although they do not replace the mount that you broke) just some food for thought
Best of luck in solving your problem. I remember buggering up my rear shock mounts in my old cherokee. Had to cut the floor to get an access hole... it definitely was a low point in my day.
2014 JKU Sport - Wife's Mall Crawler on 35s. Badlands Winch, 2" Coil Spacers, 1" PA BL
1999 F250 7.3 - 290K Miles and Counting "I am not going to censor myself to comfort your ignorance."
after pulling out the other side to see what the threading was originally in, probably not. besides, same problem as the Easy-Out...tap will be too short & won't be able to grip it. the hole is like 3" deep and a we bit over 1/2" wide.
the only other option i see is lift the whole body off the frame, and cut the bottom of the channel out, fix it, then weld it back in. same difference as cutting a hole in the floor, without the need for a car lift.
well...looks like i should check the liner in my HH140 and make sure gas works.... never done sheet metal welding...this should be interesting.