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Old 12-31-2011, 06:20 PM   #1
2.5L>4.0L

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My first mod thread.

Bumper is rusted on. My grandpa is coming over tomorrow to finish. So far. Took it out of the box and removed the lights off the bumper.
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Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-01-2012, 04:16 PM   #2
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Problem. PB blaster did not work. HOW DO I GET FRONT BUMPER OFF????

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33" Dick Cepek Crushers (Muddin Tires!!!!)
Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-01-2012, 04:19 PM   #3
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Keep spraying them for a few days and let them sit. Eventually they will budge.
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Old 01-01-2012, 04:23 PM   #4
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Smack that bitch with a sledge hammer that is if you don't plan on keeping it. And make sure u got all the bolts off. There's is one on the bottom side on each frame mounting point
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Old 01-01-2012, 04:29 PM   #5
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Buy an angle grinder. If you live in the rust belt, it will quickly become your best friend when bolts won't budge.
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Old 01-01-2012, 04:32 PM   #6
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Isnt the only thing just the head of the bolt on the underside or is their something else on the inside of bumper that needs to come off?
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33" Dick Cepek Crushers (Muddin Tires!!!!)
Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-01-2012, 05:08 PM   #7
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Been beating the shot out of the head of the bolts and ain't moving. There is nothing coming through on the other side.
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1997 Jeep Wrangler SE
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33" Dick Cepek Crushers (Muddin Tires!!!!)
Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-01-2012, 05:26 PM   #8
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there is like 2 bolts ontop and 2 bolts on the bottom on each side If I remember. They are going to be rusted to shit on the bottom depending on where you live so god bless! lol I couldn't get them I needed a strong friend to do it.
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Old 01-01-2012, 06:01 PM   #9
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Heat them up and they should come right out
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Old 01-01-2012, 06:09 PM   #10
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Heat them up and they should come right out
That's a very good suggestion so long as it is heated up enough.

Make sure to use a good quality fresh T-55 and with an adapter so it can be mounted onto a 1/2" drive ratchet wrench or, better, a slightly longer breaker bar. Those particular bolts will be too tight for a 3/8" drive wrench.
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Old 01-01-2012, 07:20 PM   #11
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There are no bolts on top side so they are over torqued. Taking to body shop tomorrow
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Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-01-2012, 07:32 PM   #12
Knows a couple things...

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There are no bolts on top side so they are over torqued.
Huh?
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Old 01-01-2012, 07:44 PM   #13
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Quote:
Originally Posted by TBrownSTL
There are no bolts on top side so they are over torqued. Taking to body shop tomorrow


You can get them. Keep at it. Use the good advice given from everyone.
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Old 01-01-2012, 08:08 PM   #14
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I've done everything everyone has said. I have applied 200 foot pound torque an still not budging. Need and air wrench. Take 10 seconds to get it off.
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1997 Jeep Wrangler SE
4 inch SKyjacker Hydro 7000 Lift
33" Dick Cepek Crushers (Muddin Tires!!!!)
Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-01-2012, 08:42 PM   #15
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did you try the grinder?
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Old 01-01-2012, 08:43 PM   #16
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I had my sway bar links rusted on and i got a torch and heated them up really hot then hit the bolts out with a hammer
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Old 01-01-2012, 09:03 PM   #17
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Everything but grinder. Don't want to buy a grinder to use only once.
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4 inch SKyjacker Hydro 7000 Lift
33" Dick Cepek Crushers (Muddin Tires!!!!)
Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-01-2012, 09:28 PM   #18
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Trust me that won't be the only use you have for the grinder! You can get a cheap one from harbor freight if you don't want to put alot into one. Put a little more time into it, heat it with a torch, use a hammer to tap it to help break it free, generous amounts of penetrating oil ( be careful of oil and torch). When all else fails the old trick of putting tension on the bolt with your wrench and tapping with a hammer simultaneously like an impact wrench.
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Old 01-01-2012, 09:47 PM   #19
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Quote:
Originally Posted by TBrownSTL View Post
Everything but grinder. Don't want to buy a grinder to use only once.
If you have one component rusted on now, I can guarantee you'll have more. You probably won't use it just once. It's an invaluable resource when you live in areas where cars rust.
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Old 01-01-2012, 11:25 PM   #20
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I've done everything everyone has said. I have applied 200 foot pound torque an still not budging. Need and air wrench. Take 10 seconds to get it off.
You don't want to use an impact on a rusty torx bolt. Both will be stripped in seconds.

You are not the first to have this type of problem. A small propane torch can be purchased at any hardware store for very little. Heat them up good.

These bolts are self tapping and installed with an impact at the factory. They will come out hard the entire way. Once you get them out replace them with button head cap screws. 1/2-13
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Old 01-01-2012, 11:46 PM   #21
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I always find that everytime I buy a new tool to do something to the Jeep I seem to find more and more uses for it. Then I wonder how I ever got along without that tool in the first place. If it was mine I would buy a grinder (I already have one for this purpose) and use it to remove the bolts. It won't be the only time you will need a grinder for your Jeep.
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Old 01-02-2012, 12:16 AM   #22
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Try a big dull chisel
a 4lb maul and a 5/8" cut chisel with the tip grinded flat or worn can work wonders.
Dont use a sharp chisel it will cut the metal fast

with a chisel strike a line stright down on the bolt face on the right side

then put the chisel at about a 45 degree angle on the right side of the bolt but the chisel needs to sit in the groove you just made

Hit the chisel hard,the energy produce from the 4lb impact will shockload the bolt and can unscrew it and break it loose

I do this alot as I'm a heavy equipment mechanic.A 4lb maul will put down 10x's more than you can.
I'll see if i can come up with some pics to show you but I think I explained it well
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Old 01-02-2012, 12:23 AM   #23
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I lol'd at the taking it to the body shop comment...
Honestly they're going to charge you what a brand new dewalt grinder will cost you.
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Old 01-02-2012, 12:35 AM   #24
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alright I went in the shop for ya

use atleast a 4 lb hammer,maybe a huge ball pen will do it

to dull your chisel place the back of it against your bumer and hit the sharp edge with the hammer,that will flaten out the point.Just enough to get rid of the point.
A sharp chisel will cut the bolt and not unscrew it.
Now hit stright down,it may take several hits to make a line thats about 1/16" deep on the right side only.Like this

Now that you made the line/mark,make it deeper
Notice mine isnt deep,I only hit it once on a soft bolt so you get the idea

now whack away slowly,if the bolt starts to unscrew you have to turn with that cut to keep the hit going all the way around.but put the chisel only in the cut and angle the chisel so that the impact is forced to unscrew the bolt
similar to this angle but you may have to lay the chisel down more

pay attention to the bolt to make sure that the chisel isnt just peeling the bolt away,if so that means that you are at too steep of an angle.
If it peels away make a new line somewher and repeat.

please wear gloves and saftey glasses.When metal is sheared with a chisel it reaches extreme speeds and can enter you flesh.If your hand slips it could slide across that bolt you just cut up and that cut will be sharp.
also I have had cheap chisels break apart and when they do its like being shot with a pellet rifle.People go to hospitals to get metal from chisels or iron removed all the time
it may also help to angle the chisel a lil half on the side and top of the bolt
this is the exact angle I would hit to unscrew,this way as the bolt turns I can keep the force concentrated at that angle
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Old 01-02-2012, 12:53 AM   #25
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Will that work on a trox head bolt?
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33" Dick Cepek Crushers (Muddin Tires!!!!)
Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-02-2012, 01:22 AM   #26
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Will that work on a trox head bolt?
yes but the bolt will have to be replace if you ruin them

I've been using this methood since the early 90's with sucess


You can also try a cheap propane torch from lowes
heat the entire head of the bolt only and then try to unscrew it

sometimes heating it until it glows and letting it cool works.
when you heat metal it expands,heating the bolt will pretty much try to expand inside the tight hole,crushing all rust inside if any.But be aware that heat will melt plastic.

and most Jeeps cant be built without a grinder.
with the right tool All jobs are eaiser.

you could also grind a slot or cut one with a hacksaw,like a flat head screw,then hit the chisel in the slot you made using the method I posted pics of.
I'm in no way promising you my method will work.Your bolts may just be too tight.But I wouldnt grind the heads off cause then your problem is still there(unless there are nuts on the bottom of these bolts)If the bolts are in a threaded piece of steel the after the heads and bumper are off.....you still have to remove the studs with no heads....which is a harder process
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Old 01-03-2012, 11:37 AM   #27
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T, you shoulda hit me over the weekend! I'd have had you drive over to the house and we would have hit that thing with the impact wrench to see if we could get it off for ya! If you don't get it this week let me know and we'll see what we can do this coming weekend.

Mac
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Old 01-03-2012, 11:40 AM   #28
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Quote:
Originally Posted by Mr Mac
T, you shoulda hit me over the weekend! I'd have had you drive over to the house and we would have hit that thing with the impact wrench to see if we could get it off for ya! If you don't get it this week let me know and we'll see what we can do this coming weekend.

Mac
Thanks for the offer. I had to have 2 bolts cut off then they came loose. Got it finished last night. It looks mean. I have a stock front bumper now if anyone needs one.
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Walt Disney World Jeepin!!!
1997 Jeep Wrangler SE
4 inch SKyjacker Hydro 7000 Lift
33" Dick Cepek Crushers (Muddin Tires!!!!)
Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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Old 01-03-2012, 11:43 AM   #29
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Good deal! Only one thing, though...it's hard to see from here!
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Old 01-03-2012, 11:45 AM   #30
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I know I know. Taking pictures when I get home after work today. I also got my soft top installed this weekend. Me and my dad did that. It was fun.

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Walt Disney World Jeepin!!!
1997 Jeep Wrangler SE
4 inch SKyjacker Hydro 7000 Lift
33" Dick Cepek Crushers (Muddin Tires!!!!)
Smittybilt SRC Front Bumper with soon to be ordered Tiger Shark 9500 Winch on the Front!!! Light Bar on top. Hi lift jack on hood!! 12 inch subwoofer and 300 watt amp behind the back seat. Hits hard with the top down!!! I LOVE MY JEEP!!!!!!!
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