Broken body mount bolts

[Joe.B]

So I was going around testing to see if I could get my body mount bolts out for a body lift I want to do in the future and I ended up breaking 2 of them I stopped after I broke the second one (should have stopped at 1) but I broke the rear most passenger side bolt and the drivers side middle bolt under the door. Any suggestions on how to fix it. I was was thinking drill them out and re tapping them but I know some of the areas you cant really do that. I'm also scared ill break more of them off if I try any others which I don't want to do. I'm just gonna soak them in pb blaster for the next moth and hope they don't snap

 

[IrishWake]

I broke the driver-side middle bolt like you did. I had actually forgotten about it until now... next time I'm in a shop ill see if they can extract it, I just haven't been in a shop lately.

As far as the rest go, after I snapped that one, I drilled little 1/8" holes above all the other body mount bolts I couldn't reach with an aerosol can straw. The two important ones for me were the ones near the rear shock mounts (another trouble area). After getting the bolts out, I cleaned up the holes, painted the edges, and put rubber plugs back in. I've never had luck using PB Blaster on this jeep, i swear by the Industrial sized cans of Aero Kroil (and to a lesser success rate, CRC FreezeOff)

 

[rasband]

I would soak the rest in kroil or liquid wrench (the latter one I’ve not used but heard good things about). Get above them, since you want the threads to be penetrated. How I would address the broken bolts really depends on where the old bolts broke, if there’s enough shaft left you could get a vice grip on it to maybe make some progress if you lift that side up after getting the others loose/off.

 

[Joe.B]

I would soak the rest in kroil or liquid wrench (the latter one I’ve not used but heard good things about). Get above them, since you want the threads to be penetrated. How I would address the broken bolts really depends on where the old bolts broke, if there’s enough shaft left you could get a vice grip on it to maybe make some progress if you lift that side up after getting the others loose/off.

I was hoping there was enough I could weld a nut on to it but it broke pretty far up

 

[Joe.B]

I'm also concerned about the bolts by the shocks. living in MN there's definitely been a lot of salt up there. is there a easy way to get to it from the top so I could spray some penetrating oil onto them?

 

[FarFire70]

I had previously installed a JKS BL and recently went to put in the Savvy lift (too much deflection with the JKS rubber pucks).

I had failed to use anti-seize on the bolts when putting in the JKS BL. I broke 3 bolts. Picked up a welder (I went expensive but a cheapie from HF would work). Got 2 of the 3 out by just welding on a nut to the remaining bolt shaft (welding heat broke them lose).

The third didn't leave enough shaft to successfully weld a nut onto (tried 3 times). I ended up dremeling it out and then welding a nut to a washer and then welding the washer where the old body mount 'nutsleeve' was. I was very careful to only cut out enough of the existing nutsleeve to just fit the nut (kept enough torque box material for the washer to be welded onto). The ~1/16 the new washer added below the torque box didn't concern me, given how much flex exist in the body to accompany this.

Rust sucks...

 

[IrishWake]

I'm also concerned about the bolts by the shocks. living in MN there's definitely been a lot of salt up there. is there a easy way to get to it from the top so I could spray some penetrating oil onto them?

This is where I drilled to get oil on top for those bolts on mine. Its this little flat "keyed out" part near where the rear seat comes down and rests. If I remember correctly, the bolt came up right in the center of this rectangle

 

[Farmergreg]

So I was going around testing to see if I could get my body mount bolts out for a body lift I want to do in the future and I ended up breaking 2 of them I stopped after I broke the second one (should have stopped at 1) but I broke the rear most passenger side bolt and the drivers side middle bolt under the door. Any suggestions on how to fix it. I was was thinking drill them out and re tapping them but I know some of the areas you cant really do that. I'm also scared ill break more of them off if I try any others which I don't want to do. I'm just gonna soak them in pb blaster for the next moth and hope they don't snap

Soak and soak, I did this for several weeks before tackling mine. A small hole to be able to spray into the threads is a great suggestion. My rear passenger body mount broke the nut plate off inside. I had to cut an access hole from the inside and then weld the nut plate and then the access hole back shut.

 

[Joe.B]

Rust sucks...

thank for the advice and yes it really really does suck

 

[FarFire70]

I'm also concerned about the bolts by the shocks. living in MN there's definitely been a lot of salt up there. is there a easy way to get to it from the top so I could spray some penetrating oil onto them?

My 3 were along the frame near the doors. The ones near the shocks came out smooth.

With that said, I later dropped the gas tank skid and it had considerable wear from salt/road debris and its bolts broke on removal. Hopefully the BL bolts nearby are high up enough to stay clear of the road salt soak...

I'm also in the rustbelt but over on the east coast.

 

[Joe.B]

This is where I drilled to get oil on top for those bolts on mine. Its this little flat "keyed out" part near where the rear seat comes down and rests. If I remember correctly, the bolt came up right in the center of this rectangle
View attachment 272560

sweet thanks ill be doing that tomorrow

 

[Joe.B]

Soak and soak, I did this for several weeks before tackling mine. A small hole to be able to spray into the threads is a great suggestion. My rear passenger body mount broke the nut plate off inside. I had to cut an access hole from the inside and then weld the nut plate and then the access hole back shut.

I'm gonna have to probably do that for both sides doesn't seem to bad tho I have a welder so I should be fine

 

[Joe.B]

My 3 were along the frame near the doors. The ones near the shocks came out smooth.

With that said, I later dropped the gas tank skid and it had considerable wear from salt/road debris and its bolts broke on removal. Hopefully the BL bolts nearby are high up enough to stay clear of the road salt soak...

I'm also in the rustbelt but over on the east coast.

I'm hoping if I take my time and soak stuff enough I can work them out. I feel by the time I'm done with this jeep every bolt will have been replaced because of how many I've broken

 

[Farmergreg]

I'm gonna have to probably do that for both sides doesn't seem to bad tho I have a welder so I should be fine

If you get the body lifted up, you can spray the top of the shock absorber mount between the gap. I had one shock bolt break off also, drilled it out and ran a bolt through.

 

[FarFire70]

Soak and soak, I did this for several weeks before tackling mine. A small hole to be able to spray into the threads is a great suggestion. My rear passenger body mount broke the nut plate off inside. I had to cut an access hole from the inside and then weld the nut plate and then the access hole back shut.

Having a JKS BL installed would have told you directly where to drill....

You can see why I'm going Savvy...

 

[Farmergreg]

I'm thinking @IrishWake suggestion of drilling a 1/8 hole and getting the penetrating oil onto the treads is an excellent one!

 

[FarFire70]

I'm hoping if I take my time and soak stuff enough I can work them out. I feel by the time I'm done with this jeep every bolt will have been replaced because of how many I've broken

I didn't find a way to soak the torque box ones. The rear most on both sides may be accessible from the rear wheel well. The other 2 are fairly sealed up.

 

[Farmergreg]

Having a JKS BL installed would have told you directly where to drill....

View attachment 272563

View attachment 272564


You can see why I'm going Savvy...

Man those really collapsed!

 

[Joe.B]

Having a JKS BL installed would have told you directly where to drill....

View attachment 272563

View attachment 272564


You can see why I'm going Savvy...

good think im not going with jks

 

[FarFire70]

Man those really collapsed!

Live and learn. I feel bad when folks on the forum post their about to put on a JKS. Year of TJs have taught the community many leasons.

OP - Didn't see which BL you're going with. Please learn from the community. Saavy is a recommended product for a reason.

When I removed my JKS, I threw it in the garbage. I couldn't look at myself if I resold it to another TJ owner.