boycecd

Got 2001 sport and went to change rear shocks and upper bolts broke off! What is the best way to get bolts out ?

Rockfrog

Air chisel the weld nuts out, fish bolt down through the cross member. The is room to fish a bolt I there ... I used 3/8" bolts. It's actually easier than it looks.

77olds

This, a million times this.

Do NOT let anyone here try to make this sound like a big deal, it's not. Do NOT cut holes in your floor, you don't need to get out the welder, you don't need to do ANYTHING major.

A hammer and a punch or an air hammer with a punch bit will knock out the nuts, which are welded to the inside of the cross member.

After they're gone, you can use a piece of thin wire or two of those retractable pen magnets - one to push the bolt, the other to catch it and pull it through the hole. You can easily get an end wrench in there to hold the bolt still while you tighten the nut.

Not a big problem, you'll be fine.

mopey2000xj

I made the mistake of cutting the floor the first time! Wasn't necessary!

XJlimitedx99

I also am currently dealing with this problem. I tried for a few minutes with a hammer and chisel but I didn't get very far. I'm going to go buy an air hammer tomorrow

mopey2000xj

Air chisel makes quick work of it

XJlimitedx99

Well I got them all out. If you don't have an air hammer don't even waste your time with a BFH. It took me a good half hour to get all 4 out with my new harbor freight air hammer. They're out though, new grade 8 bolts and bilstien shocks going in

DieselD

The HF air hammer didn't work on mine, tried for about 4hrs didn't even budge. We have a pretty good size compressor too.

Just ordered some good drill bits so I'm finally gonna get that other shock on my 99 lol.

XJlimitedx99

Dangggg, 4 hours? Those suckers are in there good. This is what they look like when they come out















5/16-18 x 1 1/4" grade 8 bolts with lock washers

PurpleToxin505

Damn, It took me about 10 minutes to pop out all four. I used the shaft part of an old adjustable screw driver for a punch and a pretty small hammer(like 2 hands wont even fit on the handle). A couple good smacks and bam they were out. Although I couldnt get a wrench to the bolt head. I just used the double nut trick to hold it.

DieselD

Nice. Slather some anti seize on there. Or one better do some BPEs

PurpleToxin505

Or even some of Detours shock cheaters

dmill89

X2, I used an air-hammer (a cheap Home Depot "HDX" brand one, probably the same as what HarborFreight sells)on mine and it took less than a minute per side. I guess some had more/better welds in the factory than others.

DieselD

I got an overachieving worker on mine then lol

boycecd

Thanks everyone for repair solutions to broken bolts going to air hammer them out and replace ! Thanks you !