I went to take off a bolt to install a transfer case drop kit on my cherokee and the bolt snapped. Is there any way to fix it without drilling and tapping the hole?

 

is there enough of the bolt to grab with a pair of vice grips? If so, what you can do is get some heat(propane, mapp, etc) and heat the crap out of. get is as hot as you can, then blast it with the garden hose til its cooled completely down, then try to wiggle the bolt back and forth and work it out. If it doesnt loosen up, heat it again, and then cool it. This method worked for me on a Ford Explorer cross member bolt when I had to do a fuel pump on it. what this is going is shocking the nut and bolt with hot and then cold and hopefully breaking the tension between the nut and bolt

If there isnt enough for you to get a pair of vice grips on, you can use a dremel and cut a small slot in the bolt, and then heat and cool the area, and use a flat tip screw driver and try to work it out,...

OR!!!! you can hammer out the welded nut and fish a new nut in its place,....

or drill it out,... .all are options

 

reverse drill bit and heat. worked great for me.

 

on cherokees, there is one stud and one bolt on each side.

if you have a welder, you can weld a washer to the broken bolt/stud then weld a nut to the washer. the heat from the weld should break the bond so you can use a socket to get it out. then just replace with two bolts.

 

i don't think all model years have one stud, one bolt.

 

Is one stud, one bolt strong enough? Thats what mine has

 

in stock form, no transfer case drop, the stud/bolt is fine.

but if you install a transfer case drop, the stud isn't long enough, so you need to remove it and use a longer bolt instead.


as far as i know, at least all cherokee's i've encountered came stock from the factory with a stud on the front side and bolt on the rear side of the crossmember.