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Old 12-08-2019, 01:00 PM
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broken rear sway bar bolt removal suggesstions

Hi Jeepers,

Could use some guidance on removing a broken bolt on the rear of a 12 JKU sway bar bracket to frame.

The bolts are the ones that hold the sway bar bushing clamp to the rear frame rail. Loosened one, and when trying to loosen the second, the head twisted off.
Turns out they are super rusty.

Anyways, the nuts are inside the frame in the rear.

I can't be the only one to have done this...

Any suggestion or insight would be appreciated.

Not sure penetrating oil is going to work as the others are severely rusty as well.

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Old 12-08-2019, 01:08 PM   #2
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You’ll need to get a set of reversed drill bits and extractors and learn to use them or have a shop do it

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Old 12-08-2019, 08:02 PM
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hmm. seen the vids on that. seems like its an overthought way of doing it.
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Old 12-08-2019, 08:53 PM   #4
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For the rest, lots of penetrating oil. Also hit the end of the bolt head with a hammer before trying to remove it. Several sharp blows helps a lot. Also go both directions (threading in and out) to work in the penetrating oil so they don't break after you get them started.

For the broken one, penetrating oil. You can try some sharp blows with a punch then use the extractors as mentioned by Victor Ward.
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Old 12-08-2019, 10:17 PM   #5
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hmm. seen the vids on that. seems like its an overthought way of doing it.
Then bring it to a shop, they’ll use an extractor...
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Old 12-09-2019, 09:50 AM
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I'm sure your right Victor, it's probably the only way.
Just trying to see if anyone has a better idea involving normal garage tools.

I'll just pay a mechanic instead of buying something else.

Lots of penetrating oil was my big mistake from the start, everything else broke loose so I didn't spray any.
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Old 12-09-2019, 11:00 AM   #7
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Originally Posted by OhioJKDad View Post
I'm sure your right Victor, it's probably the only way.
Just trying to see if anyone has a better idea involving normal garage tools.

I'll just pay a mechanic instead of buying something else.

Lots of penetrating oil was my big mistake from the start, everything else broke loose so I didn't spray any.
is the bolt broken off in the hole are is a portion of it protruding? If broken off inside the hole get a cobalt bit and drill it out and retap the next size up. If protruding can you get a vise gripes on the stud? if you can use lots of heat and get it out that way. Also you could weld a nut on the stud and try that. There are lots of really good YouTube videos out there as well.
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Old 12-10-2019, 05:19 PM
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Thanks JADMT for the reply.

It broke off just below the surface of the frame, so it's recessed.
I think your idea to drill out and re-tap would be the best option for me, I have tap and die sets.
I seen lots of videos, as you stated that showed the extractor and welding on a nut etc. unfortunately,don't have access to a welder.

PIA rusty bolts. Worst part is working upside down, a lot easier 30 years ago.

Thaks for the suggestion. That crossed my mind early on, then I forgot about it.
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Old 12-10-2019, 05:24 PM   #9
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Weld a nut to it and remove. I have found this is almost foolproof and prefer this method over trying to drill out, reverse drill, etc.....
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Old 12-18-2019, 07:58 AM
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Update:

The Nuts that the rear sway bar mount is bolted to are only held in place by a couple of tack welds. A quick hit with the air chisel to the nut with broken bolt and the entire thing was removed. Since there is an access hole in the frame where the nuts are, it's easy to just hold a new nut in place and reassemble.

Preparation, two days of bugging the forum.
Actual time working, less than 20 seconds including inserting the chisel
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Old 12-18-2019, 08:11 AM   #11
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Update:

The Nuts that the rear sway bar mount is bolted to are only held in place by a couple of tack welds. A quick hit with the air chisel to the nut with broken bolt and the entire thing was removed. Since there is an access hole in the frame where the nuts are, it's easy to just hold a new nut in place and reassemble.

Preparation, two days of bugging the forum.
Actual time working, less than 20 seconds including inserting the chisel
I had one of those nuts break free when I was removing that sway bar bracket. It was a bit of a pain, as I had to cut the bolt so I could remove the nut and replace it. I also did not weld the replacement nut in place. Thought about it, but it had already been too much trouble.
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Old 12-18-2019, 08:30 AM
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Your right Guzzi Moto.

PS a 78 yr old retired engineer I worked with years ago still rides his newer Moto Guzzi everyday he can. Ran into him right before Thanksgiving as he was picking up a few items from the grocery.

It would definitely be nice to age that well.

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