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Old 06-08-2010, 09:01 PM   #1
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Broken Body/Frame Bolt

Guys, I have a problem... Just bought some step bars and I tried to install them tonight. The brackets bolt in under the bushings where the body mounts to the frame. The first bolt came out fine. The second one gave me a bit of resistance and snapped in half. So now I have part of the bolt up in the body that I need to get out. I can't get to the bolt through the top, only through the bottom.

Here's my plan: spray PB blaster up in there every day for a few days and give it a good couple of whacks with a hammer and punch to try and loosen it. Then, drill a hole in the bolt and use one of those screw extractor bits to remove it.

Does this sound plausible? Anyone have any other ideas? Assuming I get the bolt out, where can I get a replacement? Jeep dealer?

Thanks guys.

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Old 06-09-2010, 12:35 AM   #2
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Is it able to be seen from inside the jeep?


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Old 06-09-2010, 12:37 AM   #3
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You can get replacements from any hardware store, just bring in one off the old bolts and get the same kind, Grade 8 of course.

And while your at it, if your taking out the 6 bolts on either side, it might not be a bad idea to replace the others as well
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Old 06-09-2010, 09:13 AM   #4
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Thanks Vaultzz, I'll take one of the other bolts in and see what I can find.

jp'rs: no, inside the Jeep there is just a bump in the body but no access to the bolt. FWIW, this is the body mount bolt directly in front of the rear tire on the driver side.
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Old 06-09-2010, 10:02 AM   #5
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All I can say is, good luck trying to drill that baby out! I broke a couple bolts on the interior of my jeep taking the back seat brackets out and NO DRILL BIT COULD GET THROUGH THOSE SUCKERS!!! I broke at least 5 bits trying to drill them out! I bought $60-70 worth of harrdened steel drill bits and still no progress was made... those suckers are HARD! I ended up giving up on the bolts and drilling new holes and using new nuts and bolts... But, I don't know how old your Jeep is, might be easier... But GOOD LUCK! That does sound like a good plan. You can get replacements at a hardware store, just bring the old bolt to get the right size
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Old 06-09-2010, 04:23 PM   #6
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Go slow and use lubricant. Once you see smoke your drill bit is smoked. I just drilled out 2 rear shock bolts. Took alot of patience and quite a few bits. It's a real pain in the ass, but I would guess it's not the last time I'll be drilling bolts. I would be really careful with those bolt extractors. From what I hear, once they break off you are beyond screwed (no pun intended). Good luck dude.
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Old 06-09-2010, 05:26 PM   #7
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Another alternative is to weld a nut on the broken bolt and then just take it of with a socket (and don't break this one this time )
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Old 04-24-2011, 06:46 PM   #8
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For future reference, regarding the broken body-mount bolts, I have access to minimal tools but like to do things myself. I broke 4 of the 11 bolts, as I don't have any real heat to put on those shitty bolts, (*Dear Daimler-Chrysler/ Jeep, please use galvanized steel or stainless steel bolts where they may prove useful, thanks, EVERYONE WHO OWNS A JEEP.) I took a 90 degree pneumatic cut-off tool and made 3 sided cut above the body mounts so I could peal back the sheet metal and find the broken area... I then used a cut-out drill bit large enough to totally remove the old broken bolt/nut combo and placed very thick "fender-washers" where the old body-mounted bolts were... Having the metal pealed back gives you complete access to your work area so just throw on some thread-lock when you get to the point of actually putting in your new bolts. When finished, buy a piece of sheet metal from your local hardware store, cut to about 1" larger than your 3-sided area and rivet/screw into place (or have a buddy weld up your mess). I know this is late by about a year, but I've owned lots and lots of Jeeps and this is the best solution I have (considering the fact that you don't have a set of torches to use!).

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Old 04-25-2011, 02:34 PM   #9
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We, too, are in the process of installing steps. The middle bolt on the driver's side was rusted into the washer, which is somehow layered in the floor pan. Ended up using a cutting wheel make a 3-side cut above the mount as BeenJamin did to get at the bolt through floor from the inside (and accidentally ended up just exactly where we needed to be). Had to drill another hole and use a punch to hold the washer in place so the breaker bar would get the **** bolt lose. Only broke one bolt at the back passenger side fender. Went to the dealer to get new bolts. They are now calling Chrysler because there is nothing in their parts list about body mount bolts. Very much appreicate the idea of just going to the hardware store. I guess we're a little naive expecting the Jeep DEALER to have actual parts for a Jeep. Other than taking bolts with us, which we will obviously do, anybody have specifics on replacement bolts you've bought?
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Old 04-25-2011, 03:36 PM   #10
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The bolts do have part numbers.... The 6 main bolts are J4007571 1/2-13 x 3.75 hex flange nuts.

Clicking the Thumbnail doesn't seem to show the whole attachment. Google xxTJ.pdf, where XX is the year of your Jeep, for a parts list.
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Old 04-28-2011, 11:08 PM   #11
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Here is what I learned this week about body mount bolts for a '95 Wrangler.
(1) No one at my Jeep dealer know anything about working on a 95;
(2) The current Jeep parts catalog does not show any body mount bolts for a 15-year old vehicle and the parts guy had to call his expediter at Chrysler to find out the old part numbers and to find out if they are still available;
(3) The old part numbers have been replaced. AND instead of having four bolt sizes there are now two and no one knows (a)what size bolt goes up front; (b) if the shorter bolts fit where they are needed (Yes, four different sizes are on my non-lifted Jeep. As much rust as there is they have to be original. Side bolts are one size; bolt over axle is different; bolt at back bumper is yet another size; and the front bolt is the smallest).
(4) Daystar does not sell factory bolts;
(5) Crown Automotive does not sell factory bolts, nor are they able to get them;
(6) Fastenal does not show these bolt sizes in their catalog and said they could not get them;
(7) There are no hardware stores in Johnson County, Kansas that carry grade 8 hex bolts in these sizes;
(6) Chrysler should have enough money to pay off their bail-out loans. Factory bolts for the side body mounts (need 6) are $15 EACH. The other four bolts are $9 EACH.

No choice for me; the bushings crumbled in my hand so must be replaced and the original bolts, which took days of WD-40 soaking to get loose, are so grossly corroded I'm afraid they may break when I torque them.
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Old 04-28-2011, 11:10 PM   #12
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Thanks for the info 00silvertj. I forgot have this pdf on my computer. .. duh ...
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Old 05-03-2012, 07:47 PM   #13
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At least yours came out.. all mine broke on me about 45min ago....
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Old 07-07-2012, 01:16 AM   #14
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Man my bro is in for a surprise. Installed one nerf bar no problem. In working other side, bolt broke ;(
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Old 07-07-2012, 07:50 AM   #15

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You guys know to loosen all the body mounts first before trying To pull the one side apart. And of one bolt is binding, having the rest loose gives the stuck One little room to flex before breaking. Otherwise I would weld and remove before drilling. I wouldn't cut the body until another option was unavailable.

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