I am replacing the track bar on my 97 xj and noticed the bolt holes in the lower mount are slightly ovaled. Couple questions. I am going to weld in a couple washers to fix this. Should I weld in hardned washers? Also my POS has a 2" - 2.5" lift. Is it worth the time cutting off the lower mount and fabbing up a new piece that moves the track bar over? I don't want to redrill the factory mount due to breakage potential.

 

It's somewhat common, and I know guys that have done exactly that - welding washers. And given that it will just wallow out again - use the hardest ones you can. No more messing with it should be necessary.

 

You could look into an adjustable track bar. Get it aligned right, assuming youre using the stock bar. That should reduce stress on the mounts and make the washer fix last longer. Or possibly a track bar mount drop bracket, not sure at what heights it would work there.

 

I drilled out the holes to 1/2 including the trackbar hole.

Used a hardened 1/2 bolt and nut. Never have had a problem since.

 

Yup on the same boat. Drilled out my hole and RE1600 track bar to 1/2" so it's 1/2" axle 5/8" frame, solid and no issues.