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Old 01-08-2013, 10:39 PM   #1
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Rear shock bolts snapped

I was putting in my Zone 3"lift and everything was going great till it came time to take the rear shocks off... All 4 bolts snapped trying to take them out. My friend was able to drill two of them out and use an air chisel. Before we tackle the other side do you guys have any suggestions on how to approach this?

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Old 01-08-2013, 10:44 PM   #2
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Oh and since its my DD I've been forced to drive it without rear shocks. People say it should be fine but it still makes me nervous and I will feel more comfortable when I have the shocks on.

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Old 01-08-2013, 10:47 PM   #3
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Same thing happens to me. I had to lift the body off the frame a bit to drill out the bolt and cut the nut that's welded in. PAIN IN THE A$$!
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Old 01-08-2013, 10:51 PM   #4
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Same thing happens to me. I had to lift the body off the frame a bit to drill out the bolt and cut the nut that's welded in. PAIN IN THE A$$!
+1

Had to lift the body, then cut off the nuts, then put in grade 8 bolts the opposite way to mount the shocks. Major PITA.
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Old 01-08-2013, 10:54 PM   #5
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Yeah my buddy was able to get his air chisel the the side and it took about 30 min of on and off chiseling and smashing the nut with a metal rod and sledge hammer. that was after drilling 3/4 of the bolt out and that took about 45 min and 5 drill bits lol
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Old 01-08-2013, 10:57 PM   #6
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Had the same problem a couple years ago when I did mine. It took time, alcohol, swearing, patience, and several drill bits and extractors but I eventually got the broken ones (one on each side) out.
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Old 01-08-2013, 10:57 PM   #7
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How much was involved in lifting the body?
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Old 01-08-2013, 11:04 PM   #8
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Lifting the body isn't difficult.
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Old 01-08-2013, 11:09 PM   #9
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If its easier to lift the body to get them out I might look into that. But I wouldn't know where to start with that.
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Old 01-08-2013, 11:48 PM   #10
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Spray them down with PB blaster, let them soak overnight and then hit it with the air hammer. It should break it free. Then use your ratchet to work it off. That doesn't work heat it up with a torch slap a candle to it and then try to break the bolt loose that way. Big thing is getting the rust to break free on the threads.
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Old 01-09-2013, 06:18 AM   #11
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Spray them down with PB blaster, let them soak overnight and then hit it with the air hammer. It should break it free. Then use your ratchet to work it off. That doesn't work heat it up with a torch slap a candle to it and then try to break the bolt loose that way. Big thing is getting the rust to break free on the threads.
It's too late for that....he snapped them already.

I did this to mine last year when doing my lift. 3 days of soaking and they all snapped right off with very little pressure.
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Old 01-09-2013, 06:22 AM   #12
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If its easier to lift the body to get them out I might look into that. But I wouldn't know where to start with that.
For lifting the body, start with googling body lift installation instructions. it will tell you where all the body mount bolts are and how to lift the body. They are not difficult to locate.
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Old 01-09-2013, 07:14 AM   #13
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sounds like you could do rear outboard shocks and forget those stock jeep shocks. but PB Blaster is your friend when removing jeep parts.
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Old 01-09-2013, 07:26 AM   #14
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If your shock bolts are breaking, good luck with body mount bolts. I broke or spun the threadsert on four of those raising my son's tub. And those can be a real pita to fix
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Old 01-09-2013, 07:37 AM   #15
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I cut holes in the tub to get to the top on mine
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Old 01-10-2013, 11:07 PM   #16
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So I think I'm going to try and VERY carefully (bc of the gas tank) heat them with a torch or try and lift the body to get to them.
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Old 01-11-2013, 04:19 AM   #17
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Originally Posted by ddjeeper
So I think I'm going to try and VERY carefully (bc of the gas tank) heat them with a torch or try and lift the body to get to them.
It's not real settling but there is a hard plastic covering protecting the tank itself.
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Old 01-11-2013, 06:24 AM   #18
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I removed the shield from my cut off tool, ground down the cutoff wheel till it would just fit up through the top center hole of the shock mount, and cut them off, easy as butter.. I also have a 1" body lift, which gave me visual access, and enough room to get and hold a wrench while re-installing the new ones.. Good luck,, without air tools, or the 1" body lift it's not going to be easy..
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Old 01-11-2013, 06:58 AM   #19
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Originally Posted by All Terrain TJ View Post
If your shock bolts are breaking, good luck with body mount bolts. I broke or spun the threadsert on four of those raising my son's tub. And those can be a real pita to fix
that's because we have the pleasure of dealing with road salt! Same thing happened to me.... well the ones still attached to metal anyways!
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Old 01-11-2013, 12:43 PM   #20
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Yep. I had to repair about 70% of my son's frame. From front control arms back. That was a real PITA. Gotta love the great white north
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Old 01-12-2013, 07:45 AM   #21
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When I did my Zone lift, I broke 1 bolt on each side, luckily it was the outer ones. I tried many things but in the end I used a long punch and hit the broken bolt from the bottom side (shock side). The nuts themselves are just spot welded on and with a little work then should break free. Good luck..this was a huge PITA
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Old 01-12-2013, 08:08 AM   #22
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I've carefully drilled the snapped bolt out and re-tapped on all four bolts on 2 cherokees.
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Old 01-12-2013, 08:50 AM   #23
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My mom had to drive my jeep the other day and she flipped out and Sao I can't drive it till the shocks are on and I get my front end alignment. I have work and school I need to drive to lol...
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Old 01-13-2013, 03:38 PM   #24
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About 6 hours total over 2 days and about 10 drill bits later I got the bolts drilled out and the shocks on!
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Old 01-16-2013, 02:29 PM   #25
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Hell my Jeep is a rust free and I had problem with my one rear bolt, took it to the mechanic to get it out, it was worth my sanity.
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Old 01-16-2013, 06:12 PM   #26
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THE SIMPLE ANSWER... same thing happened to be- all of them snapped..'
forget drills.. I took at the gas tank ( very easy ) then with a cutting torch I burned 4 new wholes. Watch your eyes and hands but fastest way..
Then clean up whole with a drill.

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Old 01-16-2013, 06:21 PM   #27
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Hell my Jeep is a rust free and I had problem with my one rear bolt, took it to the mechanic to get it out, it was worth my sanity.
I was so close to taking it to a shop but my buddies dad said he would help. And I don't think I could have done it without him.
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Old 01-16-2013, 06:31 PM   #28
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Same thing happened here...but not all 4. Air chisel to knock off the welded on nut. Then just regular nut/bolt combo to put it back on. Less than 5 min with the air chisel did it on mine but will all depend on how good the original welds are.
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Old 01-21-2013, 08:23 PM   #29
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Originally Posted by Rubicondon53
I removed the shield from my cut off tool, ground down the cutoff wheel till it would just fit up through the top center hole of the shock mount, and cut them off, easy as butter.. I also have a 1" body lift, which gave me visual access, and enough room to get and hold a wrench while re-installing the new ones.. Good luck,, without air tools, or the 1" body lift it's not going to be easy..
I really like this idea...i think I'm going to try this out tomorrow. I stripped or busted off all 4 of the heads in the rear and then I tried drilling them out and I still couldn't free the shocks. I think a combo of the air chisel mentioned and the cut off wheel are going to be the best bet. At $65 an hour for the mechanic, I think I'll give it another shot...
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Old 01-22-2013, 04:28 PM   #30
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I took another shot and I missed...I think my sanity is more important at this point...

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