So, I had a push attachment for one of the forklifts take a dump yesterday, and had to start a repair. So, I needed to cut some bolts, to weld the threaded portion to hold the plastic scraper to the attachment. Started using a sawzall, and got through 3 of them. But the bolts are hardened steel, and I used both blades I had left, and it toasted them quick. We were also out of cutoff wheels. So, I used this:


Along with these:


To do this:


That's right folks...I cut through a hardened steel bolt, with nothing more than a grinding disk. Took less than 2 minutes. I even did it twice, just to make sure it wasn't a fluke. LOL

When you broke the bolt head off, how did you then remove the bolt from behind?

I am not going to attempt removing the bumper, as it probably has even bigger rustier bolts to contend with.

It has 4 smaller bolts actually, just a bit harder to get at (well 2 are annoying, two are easy as ****) ... When you snap the bolt head off the other side is just going into a nut strip. It a captured plate with nuts welded to it. You have no hitch so that one bolt is all there is on it. And there is no one saying they will snap. Mine never did, and I had to remove 4 per side to remove my hitch.
You cut the exhaust clamp, kudos to you ... Now you should easily be able to push the tailpipe to the side and get an extension in there. Like has been mentioned several times.
Stop over thinking everything, it's less difficult than you make it on yourself.

Rock, If he goes the four bolt method he will still have to remove the 2 hex head screws per end cap. I don't remember if there was enough clearance with the stock bumper brackets to get the nut strip out. I know that with my JCR bumper I can not get to the nut strips because it doesn't have enough clearance between the top of the upward bend in the nut strip and the bottom of the integrated mounting plate. Also my exhaust hanger bracket has always had 2 bolts in it.

If you end up shearing the bolts, the only way you will be able to remove the remaining portion of the bolt and nutstrip will be to remove the bumper. The nutstrips fit into the frame rails through an access hole that's located underneath the bumper bracket. The brackets have 4 bolts on each side. A few of them are a PITA to get to, but it's not that difficult. If the worst case scenario happens, and removing the bumper is off the table, I guess you could just go back to the coat hanger method and call it a day. Just slap a Rough Country sticker on it. Nobody will know the difference.

Just slap a Rough Country sticker on it. Nobody will know the difference.[/QUOTE]

Lol

Good news and minor bad news.

I took Basshark7's advice and just tried my 18mm 1/2" socket along with a long pipe. My plans was that if the bolt snapped, I'd just leave the other one alone, and abort this job, and stick with the coat hanger.

But, the bolts easily started to move with all that leverage. So, I am now going to order the $15 bracket and will install it this weekend. I also need to order a clamp.
The problem is that my original thread was deleted, and I can't find the link to the $15 bracket on Amazon anymore. It was something by Walker, I remember that.

Thanks for sticking with this thread, I know that n00bs can be very frustrating.

Ok, I found it.



Does anyone know the u-bolt clamp size to order?
2 1/4 or 2 1/2 ?

Good work getting the bolts out.

The U-Bolt clamp is 2-1/4".

Ken, you're the man. You're a great teacher.

I ordered this

I hope you don't plan on moving your cherokee until you get that new exhaust hanger bolted in otherwise you might lose the nut strip in the rail and end up with a very annoying rattle. If you do need to move it just put the bolts back in semi tight. Also when you do install everything again don't use the pipe, it is way too easy to over torque and accidentally snap the bolts. If you have some split lock washers laying around that are the right size, it might be worth it to put one on each bolt before threading into the nut, they apply tension to the bolt and should reduce the potential of them to back out but nothing is fail-proof.

I hope they stop deleting your threads Bimmer, they bring me great joy.

You're clearly not dumb based on what I've read, I think you just need to use some good old fasion ingenuity fella. These things you get hung up on are not insurmountable obstacles, get a little creative and think your way around these hang ups.

Congrats? I'm pretty sure they're cheaper than that at most auto parts stores. As far as your "rivet" looking thing on the exhaust clamp, its a flange nut. Also why not just cut through the u bolt itself up above the bottom of the clamp? Much easier.

Preposterous!

Just imagine !!