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Discussion Starter #1
I am currently in the process of removing my transfer case for a rebuild and SYE install.

So in the process of removing the belly skid, I found that one of the bolts holding the skid plate to the frame is stripped. See attached photos.

In the last photo it looks like the PO may have done some back yard welding adjacent to the stripped bolt. Perhaps the PO had issues with the same bolt.

I am looking for suggestions as to how to remedy this situation.

Thank you.



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This question literally pops up every week.

Unlikely that the threads are stripped. The skid plate bolts are fastened to a nutsert that is clamped to bottom surface of the frame. Rust will corrode the frame and the nutsert will no longer have enough clamping force to secure the bolt. So when you try to remove the bolt, the nutsert spins along with it.

Luckily Mr. Blane sells replacement hardware kits for this at Black Magic Brakes. He even sells them with bolts long enough to accommodate for your transfer case drop.

https://www.shop.blackmagicbrakes.com/Nutsert-Kits-03-06-Jeep-TJ_c108.htm

What you'll need to do is cut the head off of the bolt, remove what remains of the bolt and nutsert and install the new nutsert.

Nutsert Instructions

 

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Discussion Starter #3
This question literally pops up every week.

Unlikely that the threads are stripped. The skid plate bolts are fastened to a nutsert that is clamped to bottom surface of the frame. Rust will corrode the frame and the nutsert will no longer have enough clamping force to secure the bolt. So when you try to remove the bolt, the nutsert spins along with it.

Luckily Mr. Blane sells replacement hardware kits for this at Black Magic Brakes. He even sells them with bolts long enough to accommodate for your transfer case drop.

https://www.shop.blackmagicbrakes.com/Nutsert-Kits-03-06-Jeep-TJ_c108.htm

What you'll need to do is cut the head off of the bolt, remove what remains of the bolt and nutsert and install the new nutsert.

Nutsert Instructions

https://www.youtube.com/watch?v=xezuE2GK-Os
This seems like a reasonable fix. Side note, the TC drop is going away.

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You can get those to come out sometimes if you put downward pressure on it with a crowbar while you loosen it.
 

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yah that can help ^^^

if not. cut the head off. drop the skid. use the stud to smack it into the frame, then fish it out. and get a new 1.
if you cant reach in there to cut it, drill it dead center 1/8" bit x 5/8" deep then 1/4, then 1/2, it'll pop off.......or a cutting torch would be the fastest option, blow head right off of it.

clean that nasty ass rust bubble off of there too, plz....b4 you get a hole in your frame
 

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Discussion Starter #8
yah that can help ^^^

if not. cut the head off. drop the skid. use the stud to smack it into the frame, then fish it out. and get a new 1.
if you cant reach in there to cut it, drill it dead center 1/8" bit x 5/8" deep then 1/4, then 1/2, it'll pop off.......or a cutting torch would be the fastest option, blow head right off of it.

clean that nasty ass rust bubble off of there too, plz....b4 you get a hole in your frame
That nasty rust bubble is actually a crappy weld done by the PO. I will likely grind it down.

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I did the Black Magic nutsert, worked great. Check out their instructions for building a tool to set the nutsert.
 
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I used a Dremel to cut off the bolt head and then the old spinning nutsert. I didn't purchase a nurtsert tool, rather I used the trick on the Black Magic site and built a home made tool, it worked like a charm inserting the new nutsert.
 
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Discussion Starter #12
Well, I ended up cutting the head of the bolt off and the nutsert popped out. So I'll be buying a few from Black Magic Brakes tonight. Thanks for the input fellow Jeepers! O||||||||O

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