Rear Shock Mount Sheared Off

[jazz-n-tj]

While going up a easy trail (Rouse Ridge in Southern California) my buddy behind me gets me to stop because my rear shock is dangling and not attached to the axle. I get out and check it out. The bracket ripped and sheared in half. It didn't break at the weld but in the middle of the bracket. Half of the bracket is still attached to the axle and the other half to the shock. Thankfully I was able to easily remove the upper bolts (thank goodness for CA TJ) for the bar pin of the shock and remove the entire shock so that I could finish our run to the top of Thomas Mountain.

With that said, I have a couple questions. It looks like a very easy fix. I have found a couple options for new brackets. See below.

It looks like the added a relocation bracket on the driver's side (the side that broke) and it is a completely different bracket on the passenger side). Are these relocation brackets any good? If not, I probably should remove the passenger side bracket also since it is pushing it away from the axle also.

Also, since I am doing 1 side should I do the other side? I notice it is not he stock bracket on the passenger side, so it must have been replaced at some point in the past but all it is is 2 metal plates not like the stock one which is essentially a U bracket. Please see picture.

I am finding 2 different brackets. Some say for Dana44 and others just say for TJ. From what I understand the TJ Dana 35 and 44 have the same size axle tube right? Isn't it 2.62 diameter? Some of these brackets say for 3 inch axles. Please advise.

Is this a simple job for me to attempt with my buddy who is an amateur welder? If the angle or location is slightly off will it have bad results? If so, I can pay someone to weld it but I thought this might be a good opportunity to start to learn how to weld.

Curry Bracket Pair (doesn't specify an axle type)
https://www.quadratec.com/products/CE-7020.htm
Teraflex (specifies Dana 44 and Dana 60)
https://www.quadratec.com/p/terafle...7-06-jeep-wrangler-wrangler-unlimited-tj-dana
Warrior Products Pair (says for all axles)
https://www.quadratec.com/products/92000_000.htm
Crown Automotive Pair (for 3" axle)
https://www.quadratec.com/p/crown-automotive/weld-shock-mounts-3-axle-tubes
Rubicon Express (doesn't specify an axle)
https://www.quadratec.com/products/16301_4462.htm

 

[billiebob]

Weld 'er back on or do a full outboard shock mount...... and weld 'er back on.

 

[Chris]

Are you oppose to doing an outboard shock conversion? Now would be a great time, and the benefits are tremendous.

 

[jazz-n-tj]

@Chris I have heard of people doing outboarding but I do not know exactly what that is and what it entails. Is there a writeup on it? What advantages does it have? Also, is it expensive? I am currently on a budget since I have done a bunch of stuff like new drive axle and a bunch of other small things in the past month. But I am definitely open to the idea.

EDIT: I just was checking outboardinf out. It looks awesome, but it looks like a bit more than what I am looking to do right now. I just want a quick simple fix. I'm not wanting to put a lot of money into this TJ because I ultimately want to get an LJ and make it my dream Jeep. I'd rather save my money so I can eventually sell my TJ and get an LJ.

 

[taylormade73]

It looks like the added a relocation bracket on the driver's side (the side that broke) and it is a completely different bracket on the passenger side). Are these relocation brackets any good?

View attachment 148775

View attachment 148776

View attachment 148778

Ahh...the power of increased leverage on a factory bracket by a shock relocation bracket rears its ugly head. Leave the relocation brackets alone and copy what was done on the passenger side.

EDit: with better welding I hope and maybe put a backer plate on the back side so the mount is 3 sided.

 

[jjvw]

Fix the mount. Make sure your shocks are aren't too long.

 

[Chris]

EDIT: I just was checking outboardinf out. It looks awesome, but it looks like a bit more than what I am looking to do right now. I just want a quick simple fix. I'm not wanting to put a lot of money into this TJ because I ultimately want to get an LJ and make it my dream Jeep. I'd rather save my money so I can eventually sell my TJ and get an LJ.

It's not that expensive to be honest, but it does involve cutting and welding (and new shocks). Anyways, in your case then I would just fix the mount like @jjvw suggested.

 

[tworley]

For outboarding you need $200 mounts, $500 for shocks that belong in an outboard, $200 springs that work well with those shocks, its not exactly cheap.

Fix the lower mount and make sure your running the correct length shock

 

[Jerry Bransford]

My bet is the shocks are too long. Shock brackets don't normally break on their own.

 

[jazz-n-tj]

The shocks were too long before I replaced my rear springs. They are Rancho 5000 (rough and stiff-to eventually be swapped with 5000x). The old rear springs which I have a thread about, were 4 inch lift springs but were only lifting the rear 2.5 inches and there was only about 2 inches of shock shaft out and sometimes would bottom out. Now that I replaced the rear shocks I am about 3.5 inches of lift and now have 3.5 inches of shock shaft and have not had it bottom out. I figure it was just fatigued and finally let go. I also plan to do a body lift so that should help with the amount of shock shaft that is out. I have been looking at the Rancho 5000x shocks and their compressed/uncompressed lengths. I think I need their 3.5 inch shock for best performance.

Rear Shocks
RS55256 (3.5 inch lift)
Compressed length: 15.01
Extended Length: 24.67
Travel length: 9.66

RS55241 (2.5 inch lift)
Compressed length: 13.51
Extended Length: 21.67
Travel length: 8.16

My current shock length in the jeep when sitting with weight on it is approximately 18.5 inches. I am concerned getting them shorter than the 3.5 because I would loose a lot of down travel, especially if I am to do a BL.

 

[jazz-n-tj]

Also, does anyone have know for sure the diameter of the Dana 35 axle shaft? If it is 2.62" would the 3" brackets work? All the brackets I found are either 3" or don't specify a diameter.

And it sounds like I should not use a relocation bracket and if I do get rub on the axle that I should just turn my shocks upside-down and remove the bar pin and swap it to the other side.

 

[someguysjeep]

The shocks were too long before I replaced my rear springs. They are Rancho 5000 (rough and stiff-to eventually be swapped with 5000x). The old rear springs which I have a thread about, were 4 inch lift springs but were only lifting the rear 2.5 inches and there was only about 2 inches of shock shaft out and sometimes would bottom out. Now that I replaced the rear shocks I am about 3.5 inches of lift and now have 3.5 inches of shock shaft and have not had it bottom out. I figure it was just fatigued and finally let go. I also plan to do a body lift so that should help with the amount of shock shaft that is out. I have been looking at the Rancho 5000x shocks and their compressed/uncompressed lengths. I think I need their 3.5 inch shock for best performance.

Rear Shocks
RS55256 (3.5 inch lift)
Compressed length: 15.01
Extended Length: 24.67
Travel length: 9.66

RS55241 (2.5 inch lift)
Compressed length: 13.51
Extended Length: 21.67
Travel length: 8.16

My current shock length in the jeep when sitting with weight on it is approximately 18.5 inches. I am concerned getting them shorter than the 3.5 because I would loose a lot of down travel, especially if I am to do a BL.

new shocks should not change the lift height, that's not what they do. is that worded as you meant to explain it?
and a BL won't move the shocks.

put on a proper pair of mounts and correct length shocks.

 

[jazz-n-tj]

I know shocks will not lift the jeep. I had put new springs on about a week ago.

I just looked and now see that the BL won't help. I thought the upper shock mount was to the body and now see that it is actually attached to a bracket on the frame.

 

[MUDDRNR]

I'm running into a similarish problem with my rear shock relocation bracket on the passengers side. The bolt going through the bracket into the bracket on the axle is shearing off. Any ideas on why this is happening and what I do to fix it?

 

[someguysjeep]

the bolt is shearing? use a grade 8.

but this will put whatever stress is causing this onto the brackets.
so there is likely an issue, possibly with the shock travel. to long a shock or it's not positioned at center stroke, may not have much up travel and it's topping out forcing the stress onto the connections.

what do you know about the shocks?

 

[jjvw]

Fix the bolt. Make sure your shocks are aren't too long.

 

[MUDDRNR]

the bolt is shearing? use a grade 8.

but this will put whatever stress is causing this onto the brackets.
so there is likely an issue, possibly with the shock travel. to long a shock or it's not positioned at center stroke, may not have much up travel and it's topping out forcing the stress onto the connections.

what do you know about the shocks?

I've been using grade 8 which is what is shearing off. Just replaced the shocks with what was on there for 5 years before that with no problems. I'm wondering if the coil could be worn out but not sure how to tell.

 

[someguysjeep]

and your positive they are the exact same length and travel as the previous shocks? hard to think your shearing gr8 bolts and not damaging those crappy brackets.

front springs are 12" and rear springs are 8" anything more is lift. measure both rear springs make sure they are holding the same.

get your post count up so you can load pics.

 

[jjvw]

Sagging springs don't change the overall travel. Something changed with the shocks.

 

[MUDDRNR]

and your positive they are the exact same length and travel as the previous shocks? hard to think your shearing gr8 bolts and not damaging those crappy brackets.

front springs are 12" and rear springs are 8" anything more is lift. measure both rear springs make sure they are holding the same.

get your post count up so you can load pics.

Yes they are the same shocks. I know its shearing off because I stuck a magnet on it and it retained the head of the bolt. This happened first time about 4 years in on my last set of the shocks and I was thinking it was because the shock was worn out so I reordered the same from 5 years ago. I believe the lift is either a 3" or 4" I didnt install it and wish I'd gotten the paperwork from the guy. I'm inclined to get a new set of brackets and see if that fixes it. It's an 04 wrangler with 205k had it for 10 years now and this problem started about a year ago. Thanks for the input.