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Old 01-18-2017, 04:53 PM
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Rear axel side track bar bolt nightmare

Hey everybody. I am hoping someone has a suggestion that will help me complete my 4" lift kit project. I am working on a 2004 Rubicon and have had almost every bolt either frozen to a collar or break off. I finished the front and now My latest and most difficult bolt is the rear axel track bar bolt. It broke 4 torx heads and after days of trying to spray heat, bang etc it I thought in my infinite wisdom I could cut the head of the bolt of and bang it out. Not a chance thats going to happen. Since then I have cut the entire track bar to pieces and removed the outer collar and bushing but have had zero success cutting the inner collar or bolt. The space is so small that even my dremel has reached it limit. I have tried using a sawzaw which is laughable given it can't even rotate without smashing the blade to pieces. I really need some help. I will buy what ever tool I need because I am out of ideas. Thankfully this a toy and not main vehicle but I do want to use it. Any help would be really appreciated.
Thanks,
Paul

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Old 01-20-2017, 09:45 AM   #2
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Try a 4" or 4.5" angle grinder with a metal cutoff wheel in it. I think that might be big enough to reach the collar without being too big. Cut as close as you can to the bracket on each side of the inner collar. If the 4" won't reach, you may need to use a 6" or 7" right angle grinder with a cutoff wheel. Either way, you will probably need to take the guard off the grinder.

Here's a cheapy 4.5" grinder you can get at home desperate:
http://www.homedepot.com/p/Ryobi-5-5...031G/205558109

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2014 JK Rubicon X, 4.10 Auto \\ Dynatrac HD 1/2" tubed ProRock 44 w/ ProSteers \\ Yeti Tie Rod & Drag Link \\ TeraFlex front LCA Sport Flexarms \\ Custom-built Dana 44 HD rear axle, fully welded w/ Artec brackets & Ten Factory shafts \\ AEV 2” Lift \\ 255/80-17 BFG KM2 tires \\ Skid plates = LCAs, engine, trans, gas tank, evap, AEV diff slider \\ Custom rear shock, exhaust loop & x-member Skids \\ Warn Zeon 10s w/FlatLink \\ AEV Rear Bumper \\ aFe 2.5 High Tuck axle-back
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Old 01-23-2017, 03:14 PM
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Thank you for the reply jac04 but the space is way to small for that. I tried
I was able to finally get this bolt off but it was quite the challenge. I ended up finding some threads talking about how they had to remove the upper control arm so because I was out of ideas I did that. I tried to cut the bolt from the rear but I just destroyed all my dremel cutting wheels and the dremel head so that was a no go. I tried to weld a nut to the end of the bolt but again was unsuccessful because I was in a bad position under the Jeep. Finally I cut the back nut bracket and dropped the axel to a level that I could get a punch against the broken bolt and banged that bad boy out. I did have to use a slightly smaller bolt to finish the job but its out. Yay.....now time to finally move on with this lift.
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