Track bar stuck cotter pin/castle nut

[Chippy]

Trying to change my track bar and it seems I’ve hit a roadblock. The castle nut on the frame is seized because the cotter pin rusted away and is stuck inside.

I’ve tried drilling the cotter pin out but there isn’t enough room. Put a 20mm on the bolt and it ended up slipping off and 19mm is too small. Don’t wanna try again because I don’t wanna strip the castle nut and create a bigger problem.

Any advice?

 

[Jeepster09]

Sawzall and cut it off. You have limited options.

 

[Chippy]

Sawzall and cut it off. You have limited options.

What part do I start cutting? Horizontally at the base of the nut?

 

[tr21triton]

did you use a 6 or 12 point socket ? 6 point is best hammer it on there if you have to.

 

[macleanflood]

Can't be stuck if it's liquid...

-Mac

 

[Chippy]

did you use a 6 or 12 point socket ? 6 point is best hammer it on there if you have to.

6 point 20mm. It was kinda tight on the castle nut so I tapped it on there with a hammer. I thought it was about to break loose but instead it started rounding off the nut. A 19mm has no chance of going on there even with a hammer.

 

[flyinfish]

I'd start by cleaning as much debris as possible with a brush and brake-clean so you can see. Then use a punch of the appropriate size to drive the remnants of cotter pin out. Followed by a socket. If the socket won't grab it then a large set of vise-grips should do the trick.

 

[TJ Jim]

1/8” pin punch to knock the cotter pin out.

 

[tr21triton]

6 point 20mm. It was kinda tight on the castle nut so I tapped it on there with a hammer. I thought it was about to break loose but instead it started rounding off the nut. A 19mm has no chance of going on there even with a hammer.

try it again except try to tighten the nut just a little and see if it will move.

 

[BigKID]

I third knocking the remnants of the pin out with a punch. Try a 13/16 socket if you have one as it is slightly smaller than 20MM.

 

[Jeepster09]

You may end up have to replace track bar...I would try using sawzall to cut off nut [up and down] or just cut it right accross the nut and stud. You then can upgrade with adjustable track bar.

 

[Sean B]

Trying to change my track bar and it seems I’ve hit a roadblock. The castle nut on the frame is seized because the cotter pin rusted away and is stuck inside.

I’ve tried drilling the cotter pin out but there isn’t enough room. Put a 20mm on the bolt and it ended up slipping off and 19mm is too small. Don’t wanna try again because I don’t wanna strip the castle nut and create a bigger problem.

Any advice?

View attachment 678419

Try a cold chisel and a hammer. Put the chisel on the right side of the nut, and hammer the nut loose, the shock of the hammer strikes will help to jar it loose. Worst case you will eventually split the nut and it will come loose.

 

[mrblaine]

6 point 20mm. It was kinda tight on the castle nut so I tapped it on there with a hammer. I thought it was about to break loose but instead it started rounding off the nut. A 19mm has no chance of going on there even with a hammer.

You have shit sockets or aren't paying attention. The correct size of that nut is 3/4" and a metric 19mm socket is interchangeable. Not sure what else is going on, but those 2 will work.

 

[Zorba]

As far as the cotter pin goes, don't bother trying to get it out. Bust it off as short as you can, then...

Force the castle nut over it. If you can what with not getting something to hold onto it.

 

[Chippy]

You have shit sockets or aren't paying attention. The correct size of that nut is 3/4" and a metric 19mm socket is interchangeable. Not sure what else is going on, but those 2 will work.

THANK YOU! Nobody else bothered to tell me I was using the wrong size. I had to use a press tool to get the 19mm on there it was so tight from all the rust and stuff. Came right off after.

My sockets are Tekton if it matters. Not sure if this is in the shit tier or not haha. I always considered them decent enough for what I do.

 

[Zorba]

My sockets are Tekton if it matters. Not sure if this is in the shit tier or not haha. I always considered them decent enough for what I do.

I don't know either - but they got it done so they were plenty good enough!

 

[TheBoogieman]

THANK YOU! Nobody else bothered to tell me I was using the wrong size.

Nobody else here has dealt with more issues (and solved them) than mrblaine IMO.

 

[tr21triton]

THANK YOU! Nobody else bothered to tell me I was using the wrong size. I had to use a press tool to get the 19mm on there it was so tight from all the rust and stuff. Came right off after.

My sockets are Tekton if it matters. Not sure if this is in the shit tier or not haha. I always considered them decent enough for what I do.

Don't they make that gas additive? Boy next thing ya know they'll get into beer brewing

 

[Chippy]

I don't know either - but they got it done so they were plenty good enough!

Yep! Your advice worked too. I tried to punch the cotter pin out and it wouldn’t budge. So just cut it as short as I could and it ended up breaking when the bolt came loose.

New track bar is on with mrblaines stainless ARP bolt. Torqued the frame side to 60 and the ARP axle side to 55 with blue thread locker. Gonna take it for a spin soon.

 

[Zorba]

I tried to punch the cotter pin out and it wouldn’t budge.

Slather it with grease or never seeze to give it a chance to be removable next time.