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Old 07-08-2014, 06:22 PM   #1
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Rear shock mount issues

So back when I put my lift on my 04 Wrangler Rubicon we ran into a big issue, the bolts in the upper rear shock mount had fused in their holes and even with all the PB blaster and finesse in the world they still snapped. I took it to a local shop to help get me going and got screwed, they ended up using an airchisel and kocked out my factory threaded bolt holes. I now have unthreaded holes there. The shocks were secured using some speed clips and it held up for a while but now I cant get my right rear shock to stay on, it just keeps breaking free. Does anyone have a good solution for me that wont cost me an arm and a leg. I would love to relocate my shock to the outside of the frame but I dont think I have the clearance. I have a 4" short arm suspension lift running 33" Nitto mudgrapplers with 1" wheel spacers on the factory Rubicon wheels. Eventually I plan to convert to a full long arm system with a tummy tuck but its just no in the cards right now

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Old 07-08-2014, 08:04 PM   #2
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Im thinking to keep the stock location you could either plug the holes with a welder, drill them out again, and rethread them, or weld a small rectangle over the stock mounting area and drill out the areas you need and rethread the holes.

Can you put a nut and washer on the other side of the frame mount and just bolt it on that way? Ideally you would weld the nut on so its easy to remove the bolt from below later. You would probably need to lift the body up a couple of inches to do this.

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Old 07-08-2014, 08:10 PM   #3
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I paid 'Flaco' $20 and he drilled up a new hole, slightly rotated the shock, and bolted the shock in place. There has to be a solution for your shock mounting problem.
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Old 07-08-2014, 08:50 PM   #4
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You can weld on bar pin eliminators. Or, like I did, you can drop a bolt through there and tighten the nut while using something to hold the top of the bolt through the hole. You would be surprised how little force it takes to keep the bolt in place, I had no issues with mine.
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Old 07-08-2014, 09:15 PM   #5
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Quote:
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You can weld on bar pin eliminators. Or, like I did, you can drop a bolt through there and tighten the nut while using something to hold the top of the bolt through the hole. You would be surprised how little force it takes to keep the bolt in place, I had no issues with mine.
X2...You could even tack weld a flag on the bolt head.
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Old 07-08-2014, 09:59 PM   #6
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Yea I would really like to do the bar pin eliminators but wouldnt I lose a couple inches of shock travel? I am going to stop by a Jeep specialty garage near me tomorrow and see if they might be able to help me. I would love to do it myself but I dont own a welder yet. I would still like to see about moving my shocks outboard, I want to do a currie antirock system in the rear and I read that usually you need to move the shocks for that anyways so I might as well get that done now.
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Old 07-09-2014, 10:18 AM   #7
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Well apparently that place doesnt weld anymore, not sure how you can be a 4x4 shop and not have a welder, anyone know of a good shop in central nj?
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Old 07-09-2014, 06:47 PM   #8
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Had the same problem on my 97. A few years back I snapped the bolts on the p/s and was able to knock the weld nuts off. I just used bolts with nuts and washers and had no problem with it. I just installed a Savvy GTS and while I had the tank out and easier access to the upper shock bolts I figured I would put in Iron Rock Offroad's Bar pin eliminators. Of course the d/s shock bolts broke this time and I couldn't knock the weld nuts off so I had to drill them out. PITA!! Anyway, eliminators are in now and I won't have to deal with snapping bolts anymore. Lost about 3/4" up travel but I think it's worth it to not have to deal with breaking bolts anymore.
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Old 07-09-2014, 06:53 PM   #9
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I had one bolt break. I was lucky. But in the top side is a nut welded on. I drilled out the bolt and just through bolted a new bolt and nut on top. I'll try to post a pic.



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Old 07-09-2014, 10:24 PM   #10
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thanks guys, all really useful information, whats the trick to accessing the top of the shock mount easily? I thought I had to lift the body to do that. I came up with a pretty good idea im going to try after getting some other advice. I'm going to hit the hardware store tomorrow and get a couple collared nuts, drill out the existing holes just large enough to fit the nut side so the collar faces down towards the shock and spot weld them in place. Should be a fairly easy and permanent job. Now I just need to find someone with a mig welder and half a brain.
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Old 07-10-2014, 06:57 AM   #11
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If you remove the plastic inner fenderwells, (they come out easy), it will give you some access to the weld nuts. You will have to remove the gas tank for the best access. Again, not that difficult, unless any of the mounting bolts give you a hard time. Drilling out the old bolts with the tank in place you will need a long drill bit. Good luck!!
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Old 07-10-2014, 01:10 PM   #12
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My 4 bolts snapped, I used a dremel with several cutoff wheels to cut off the welded nut. The space between the bots where the top of the shock peeks through the frame provide a large enough opening to access the nuts with the dremel.

I used new nuts and bolts and used a flared end wrench with a swivel head to hold the bolt stationary while i tightened everythin up. No tub lift required, just tedious because you don't want sparks to hit your gas tank. I put a chamois up over the tank where I was dremelling.

Removing the inner fender liner is a must for sure.
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Old 07-10-2014, 03:51 PM   #13
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My 4 bolts snapped, I used a dremel with several cutoff wheels to cut off the welded nut. The space between the bots where the top of the shock peeks through the frame provide a large enough opening to access the nuts with the dremel.
Didn't think of the dremel. Great idea!!
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Old 07-10-2014, 08:33 PM   #14
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Hmm, guess I could try that, I'm also considering doing this
Nth Degree Mobility Shock Shifters - Jeep TJ
seems like a decent kit for the money plus once its done I wont need to worry about the stupid factory shock mounts and bar pins any more, install looks really straight foward
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Old 07-28-2014, 11:20 PM   #15
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Ended up getting my shock mount issue solved by Toms Machine Shop in Avenel NJ. I have to say I'm impressed, tom was able to fix my problem in about 30 min and for a more than reasonable price. He ended up drilling the holes out just a bit more and used a large specialty riveting gun that inserts high quality threaded rivets into the holes. He then used the highest quality(grade9) bolts to re secure my shock. Yeah, apparently there is better stuff out there now than grade 8. He also gave me a lot of helpful information and recommendations for future modifications. I going to be seeing him soon, he will be building me a custom stainless steel exhaust system, I just need to decide on a muffler, think im going to replace my 90k mile old cat at the same time, Thanks for all the help guys and if you in or near jersey I would highly recommend giving tom a call, he is nothing shirt from a jeep master.

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