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ClearH2O 11-14-2012 07:49 PM

Bump stop cup cup...replacement.
Ok, so after a search of threads on here I don't find any write ups on replacing the bump stop cups on the spring tower.

Mine are extremely rusty as in metal separating into flakes. I am also doing a 2.5" lift right now as well and currently the entire front end is in various pieces on the garage floor right now.

The cups themselves are so rusted that the bolt that holds the cup is not discernible to the cup itself due to the oxidation. So I cant get a socket on it at all (either side) and what I am thinking is to grab the saws all and just cut it off and then dangle a magnet down into the shock tower to retrieve the other cut half.

Any feedback on this strategy??? Any better strategies???

kfdjason7620 11-14-2012 07:58 PM

Isn't it threaded into the drop down "tower" above it? If so then the magnet wont work. You will have to drill it out. Search "wrangler jounce bumper" on ebay

UnlimitedLJ04 11-14-2012 08:10 PM

you can get a new cup & jounce from the junkyard, ZJ fronts will fit the TJ front and rear. Also crown automotive sells new jounce bumpers.

the tower is threaded, so if you somehow cut the cup off without disturbing the tower, you're still left with a bolt threaded into the tower. that you can't get off.

my suggestion is take a wire wheel on a dremel, shove that up in the cup and clean as much rust off as you can. then take a new grade 8 nut, a big one, say something that uses a 3/4" socket, and super glue it to the rusted bolt. Then turn your welder up hot and weld that nut to the rusted bolt from the inside of the nut. Wait till it cools, then grab on to the bolt with your socket and see if you can twist it out. You'll want spray PB Blaster directly into the top of the tower so make sure the bolt is plenty soaked before starting.

worst case scenario, you have to cut the tower off and build a new one out of pipe.

Irongrave 11-14-2012 08:24 PM

on my dad's rig the front bump stops were shot. one was gone and the other wasn't far behind.

We went a little crazy on the fix. We cut the old bumpstops out. Drilled a 2.5inch hole in the top then welded in a set of Air bump can's followed by bolting in a 4inch travel Sway-A-Way air bump




ClearH2O 11-14-2012 08:39 PM

Well I wasn't sure if the tower was threaded but I had a suspicion. Damn!!! Worst case scenario has now been realized.

ClearH2O 11-21-2012 11:59 AM

Ok just a wrap on how I handled my jounce/bump stop cup dilemma.

Luckily, I had a pretty simple work around. I took a pipe wrench to the cup itself as I hoped and luckily realized the rust was limited to the metal exposed to the elements. I turned to the the left and the cup and bolt moved together. From there I was able to get a pair of vice grips on the remaining bolt head and slowly back it out. In addition, the threads holding the bolt broke apart making it easier to remove but require another work around to reinstall.

For the reinstall I simply used a tap and dye set to rethread a 1/2" bolt through and then drill out the existing hole in the new jounce/bump stop cup to accommodate. 👍Bam it was done and good as new.

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