Possible solution for rear upper shock bolts

[m9199]

So, as many jeepers before me, I've snapped 3/4 of my rear upper shock bolts on my 05 due to the 13 years of salt water splashes. While researching possible solutions, I stumbled upon this part from Rough Country

It is a flag nut for an XJ to replace the welded nuts to make it easier handle.

I haven't found any pre-fabbed parts that fit the TJ, so I think I will make one if my own . Does anyone know of possible issues I might run into?

 

[Chris]

If there is anyone's input I'd value on this more than anything, it's @mrblaine.

It doesn't seem like a bad idea, but if anyone can pick something out that is wrong (or won't work well), it will be Blaine.

 

[Wrangler69]

After I got all 4 broken bolts removed I just welded a short piece of strap about 3/4 in wide to each of new bolts so when they turn they hit the frame and hold back up, easy, hardest part is getting the broken bolts out but next time it will be no big deal since nothing is welded to the frame on top which was a stupid design.


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[mrblaine]

So, as many jeepers before me, I've snapped 3/4 of my rear upper shock bolts on my 05 due to the 13 years of salt water splashes. While researching possible solutions, I stumbled upon this part from Rough Country
View attachment 81177
It is a flag nut for an XJ to replace the welded nuts to make it easier handle.

I haven't found any pre-fabbed parts that fit the TJ, so I think I will make one if my own . Does anyone know of possible issues I might run into?

No issues. Only change I would make is to use flange nuts and do a slightly better welding job than they did.

 

[m9199]

No issues. Only change I would make is to use flange nuts and do a slightly better welding job than they did.

Thank you very much mrblaine! I will post pictures of my little project as soon as I finish.

 

[toximus]

If you lift the body up slightly (which you'll probably have to do anyway to knock the remaining nut off) you can reach in and stick a nut on top.

 

[m9199]

If you lift the body up slightly (which you'll probably have to do anyway to knock the remaining nut off) you can reach in and stick a nut on top.

I'd rather not have to lift the body up whenever I replace a shock.

 

[Fughuert]

If you get the old bar pin out from between the bolt and the crossmember the bolt seems to come out easily (2 of 2 that I tried this on for me).

You can also use a worn cutoff on a die grinder to sneak in the hole where your shock sits and cut most of the nut off the top the crossmember then air hammer it off from below with the head cut off the bolt.

I then just dropped a bolt through the free hole and impacted a nut on from the bottom, no body lifting required. This seems like a waste of time.

 

[Gobucks43112]

m9199 did the flag nut work? I just talked to RC and they said it wouldnt work on an 02 TJ

 

[m9199]

m9199 did the flag nut work? I just talked to RC and they said it wouldnt work on an 02 TJ

I just installed regular nuts and bolts for now.
When I go through and replace my body mount bushings I'm going to try it out.

 

[Gobucks43112]

ok

 

[warrpath4x4]

I am getting ready to do my rear shocks, i ordered bar pin eliminators to install on mine that way i wont have to worry about it anymore.

 

[Benjeepn]

Thankfully I live in the south and haven't had any problems removing fasteners. I have not even looked at the upper shock mount close. Just wondering why a speed nut would or would not work?

 

[m9199]

Thankfully I live in the south and haven't had any problems removing fasteners. I have not even looked at the upper shock mount close. Just wondering why a speed nut would or would not work?
View attachment 86191

That's actually a good idea, but I think the only way to get one to fit would make it interfere with the shock eye.

 

[Brian83]

Why not drill the broken ones out and then install steel RivNuts?

 

[m9199]

Why not drill the broken ones out and then install steel RivNuts?

I personally wouldn't want to risk them spinning in the hope the next time I have to get to them.

 

[Brian83]

I personally wouldn't want to risk them spinning in the hope the next time I have to get to them.

If you get the correct ones for the thickness of the sheet metal they wont spin. 99% of the time when a RivNut spins it was the the wrong size for the application. Also get the ribbed steel ones and not the smooth aluminum ones.

 

[jjvw]

m9199 did the flag nut work? I just talked to RC and they said it wouldnt work on an 02 TJ

Specifically that year for this purpose? Or was RC not understanding the question and just reading the computer screen with a database result that says this will not fit?

 

[m9199]

Specifically that year for this purpose? Or was RC not understanding the question and just reading the computer screen with a database result that says this will not fit?

I'm fairly certain the XJ has a larger bar pin than the TJ, so that's why the product wouldn't work. I'm curious why this exists for the XJ but not the TJ, which IIRC, has very similar shock mounts.

 

[ErikOffroad]

I had this issue. Lucky for me I installed a 1.25 body lift so I am able to get at the back side of the holes. I cut it out with a cutoff wheel and used a air hammer to get the rest out. Then I installed it back together with larger grade 8 bolts, washers and lock nuts. You may want to consider just doing a body lift.