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Discussion Starter · #1 ·
I'm writing this in advance. I plan to install a Zone 2" BB(pucks & shocks). I've heard horror stories about the upper bolts on the rear shocks not being able to get the out. If I were to encounter such an issue, what is the fix. I plan to start now with several shots with PB Blaster. But if that proves to be futile what are my options?
 

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I'm about to start my zone lift as soon as I finish my coffee. I'm worried about the shock bolts too. I've been spraying everything with PB blaster for the past week or so. Lets hope it goes smoothly.
 

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Discussion Starter · #3 ·
Keep us posted!
 

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I didn't have any trouble what so ever with mine, but I did spray them with PB for an entire week before even touching anything, and also directly before (and during) removal. Vibration can also help it get in there. I sprayed mine down, and then drove it, hit things with a mallet, resprayed, etc. The PB definitely made a huge difference. Every bolt came out really easy, even the really gunked up ones.
 

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I've learned to be very carful with rusty bolts. Spraying PB blaster can help a lot. Steady even pressure when breaking them free and don't use a long ass breaker bar. Remember to use your anti-seize when re-installing, helps a lot the next time around.
 

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My bolts broke off for the upper rear shocks on my last Jeep. Little tip I found is if you move the plastic wheel well out of the way you can usually fit your hand between the body and get a wrench in there. Other then that, I have seen people cut a small section out of the crossmember to fit a wrench in. Good luck! lots of PB blaster
 

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If the bolts start to get stuck, tighten them and loosen them and repeat, you will eventually work the rust/gunk off the threads and get the thing apart without damaging the fasteners. Take your time and don't gorrilla it.

Or, just break it and buy new bolts...but the above works.
 

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Air tools saved me. The vibration from an Impact gun broke them loose and I was able to get them off. It was the front bump stops that gave me trouble and stripped.
 

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Haven't made it to the rear yet...still working on the front. I seem to be in bump stop hell right now. But I'm working through it and taking my time. The PO had a lift in at some point..removed it..put the old springs back in but left the bump stop extensions in place. I've been bottoming out on the smallest bump in the road. Hopefully I'll be done with the front tonight and will get the rear done tomorrow.
 

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I just did mine the driver side came out easy with penetrating oil the passenger side one stripped but didn't break and one came out several hours later with a pry bar and bloody knuckles I got it pulled out and the other wedged in place and put back in....moral of the story on the top bolts only one really needs to come out the other just needs to be loosened a few turns
 

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Air tools

Air tools saved me. The vibration from an Impact gun broke them loose and I was able to get them off. It was the front bump stops that gave me trouble and stripped.
Air tools can be a great time saver but they can also be treacherous. Iv installed lift kits on over 5 jeep tj's and at least three of those jeeps had these problems. pretty much i have learned that with air tools, it will just instantly snap them off. You should work them with hand tools ever so slightly. Use a lot of PB Blaster too weeks in advance. And if you snap them off, your pretty much screwed. You can use an air chisel and punch right through it and put a new bolt in there. Thats what i usually do. The factory upper rear shock bolts are way too small to begin with. And this is going from two years working as the suspension specialist at my local shop in town where I was the one who modified customers trucks and jeeps for them.
 

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Broke all four of mine. Pulled the body bolts, raised the body and chiseled the tack welded nuts. Installed new grade 8 3/8" bolts from the top down. Use flange nuts. Zinc coated.
 

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When I did my rear shocks I was very lucky the PO used white grease on the bolts and they came out fairly easy.
I've read so many horror story's about broken bolts I was prepared for the worst.
 

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I used PB Blaster every other day for two weeks. I pulled up the plastic wheel well and used a flashlight to make sure that I got them good and soaked. I also pulled the one grommet in the tub that is over the driver side bolts and sprayed from there. I also used Freeze-Off for the two days before removal. All four came out without a problem.
 

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Mine came out without any penetrating oil. Southern jeep in good condition, couldn't ask for better. When I put them back in I used anti-seize.

A tip for everyone though, and I'll say it in every thread I need to until I get the point across, order a couple cans of Kroil from Amazon. Kano Labs Aerokroil to be exact, 11oz can is ~$10, maybe a bit more. Yes it's expensive. But it is better than PB blaster in a way you can't even imagine until you use it. I've had mine for a couple years now and once it works in it frees up everything.
 

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I lucked out. Only snapped 1 out of 4. The one closest to the frame rail, passenger side near the exhaust. I was able to drill it out pretty easily. Tomorrow I'll probably weld a nut onto a piece of flat stock with a hole in it...or it looks like if I move the plastic in the wheel well a little, I might be able to get a box wrench or something on it.

My luck continued, and found out that the PO who took out the lift he had in there at one point, kept the rear track bar relocation mount in place and the extended sway bar links..and the bump stops. At least now I know why when I'd hit a bump I'd hear a loud banging noise and get bounced out of the seat. My suspension had just about zero up travel with all that combined with the sagging stock springs he put in.
 

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I have used Heat with my cutting torch to remove bolts and nut on a lot of things over the years,
But Do Not Use A Cutting Torch Or Any Open Flame Around the Gas Tank.

Gas Puts off fumes at Temperatures 40 Degrees Below Zero.
You may not smell the Fumes, But they could be there,

you Don't even want a Spark around Gas Fumes..

You Don't want us to Say :rip:
 
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