Heard a rattle coming from rear exhaust on 2001 XJ 4x4 Sport model. Found all exhaust system components tight and secure. Then I noticed the passenger side rear shock absorber fell off its upper mount and was rubbing on tail pipe. One tab was broken off and still secured under the bolt. The other tab still on the end of the shock.

Both upper mount bolts were still attached to body. First bolt where the tab was evidently still attached to the shock, well the head snapped off, even after having used penetrating oil and turning it a little bit clockwise, a little bit counter-clcockwise, etc. Second bolt just spins and cannot be removed but I was able to slide out the small broken off tab from underneath the bolt head.

Is there any access to the upper shock fastener area from inside the cab/floor? This is becoming a real pain. Someone else who replaced the shocks for my wife a couple of years ago took about a week to finish the job because they obviously had the same kind of problem. Don't know if they ended up using only one bolt on the top mount or two like they should have (will never know for sure at this point).

Any help, tips, or solutions from forum members will be greatly appreciated. I imagine this can't be the first time this situation arose. Thank you.

Driver side shock OK

Passenger side shock fell off upper mount

Shock mounting tab broken off.
Thank you.

 

If memory serves correct, I was able to get a combination wrench up there to hold the nut when I did mine. It took a bit of finessing, but it fit.

 

Folks typically replace them with flag nuts such as the set below from Rough Country. You can also find them on Amazon and eBay.

https://www.roughcountry.com/product...-flag-nut-1082

The nuts are just tack welded in. You can break them loose with a good hammer blow. The one that spins will need the head to get chiseled, sawed or ground off. Then you can push the remains out.

Clean and spot treat the rust before you mount the new shocks.

 

If you have problems hammering uphill, like I do, an air hammer does a great job of punching them out .

 

Thanks for the tips. I ordered a set of flag nuts which I never heard of before. Still having trouble removing the spinning bolt on one side (combination wrench on the inside won't hold enough to do any good). I have used about 6 Dremel #420 cutting wheels so far just trying to cut off the bolt head. However, although I see a lot of sparks flying with the disc, I cannot seem to even groove the bolt, let alone cut it off. Eventually, the discs break and a change i'em out for a new one. I have no idea why they are not cutting right through in seconds.

On the other side, the bolt head broke off at the end, so there is a small threaded "stud" remaining in the hole which needs to come out. I have not tackled that job yet.

 

1) that "small threaded stud" is what you need to smack on with the hammer or whatever. That will separate the welded on nut from the body sheet metal.

2) a Dremel tool isn't the weapon of choice to cut a bolt that size. Get an angle grinder.... even a Horror Fright one will work in a pinch.

 

I can personally verify that you CAN get a nut and wrench up there fairly easily, once you punch the old broken nutplate out of the way

 

Update: I gave up with the Dremel tool and after quite a long time with a mini-hacksaw, I was able to remove the loose bolt and nut. However, I gave up again after trying to remove the stuck stud/nut on the opposite side after many whacks with a piece of rebar and mini-sledge. To maintain my sanity, I quit for today and will try again tomorrow.

 

If you're going to own an old vehicle you need tools. It's really hard to swing a hammer hard enough when you're on your back under the jeep.