So yesterday I just about completed the tear down of the '91 XJ, but came to an abrupt stop when it came time to drop the rear leaf springs. The front leaf spring bolts came out easy, but the rear bolts not so much. Im pretty sure the bolts welded inside the frame have broke loose.
So I dropped the gas tank to see if the bolts were exposed, but there not . So before I cut into the frame to expose the bolts, is there anything I should consider before I start cutting?? Also, if I do have to cut, I'm going to need to weld a plate over the cut and weld a new bolt to the frame. Does anyone have a portable welder they can bring over and help me out??

I just read of a way to get the nut off of the bolt. On the underside of the frame rail, cut a slot large enoung to fit a 21mm wrench through to grip the nut that has come loose from the frame. This sounds like a pretty good idea, but the new bolt won't be welded to the frame once I install the new leaf spring shackle. I'm also thinking I want need to weld a patch over the slot cut for the 21mm wrench. What do you think??

Matt, Cut a hole just big enough to put a socket through and over the old anchornut. Pull the anchornut out thtough the hole and sling it in the weeds. Replace the old anchornut with a regular Grade 8 nut and leave the hole there so you can remove the nut in the future when needed. That small of a hole in the frame won't hurt anything. I've heard of lots of guys doing that when they've had this happen.

If you take the rear bumper off you can get access to cut the bolt off.

Well I tried the Bumper idea first, but that wasnt working out. So I moved onto making a small hole that kept getting larger. Due to the nut being in a pocket, it was tough to get both the holes lined up. So as you can see the first hole is slightly larger than the second one closest to the nut.

As for the size of the hole, i'm on the ropes as for if I need to have a plate welded over them. I do have a trailer hitch which seems to be a good reinforcement, as seen in the pics. What are your thoughts, any ideas??

So here's a pic of the new rig, the day after I got it. As you can see, I wasted no time in making room for the goods.

At some point, they'll be the exact opposite.

A friend of mine just picked up a new portable welder. So I'm gonna have him weld plates over these holes just to be safe. He was gonna bring the welder over anyways to weld on the LCA skid plates any how.

Looking good, Matt, but I've always thought that 91 XJs are the best anyway...LOL.

Hey what are your plans for the old Jeep when you get the 91 built? I really am in need of a good set of XJ front seats. My driver's seat is hashed.

Lol, the '86 seats are going in the '91. '91 must have been a bad year for seats, cuz mine are pretty thrashed too. As for the rest of the jeep, I'm gonna put it back to stock with the '91 drivetrain and thrashed '91 seats and hopefully pass it on to someone who needs a DD.

HAHAHA....my 91 one seat just fell victim to getting wet many times and having a fat guy sitting in it for a lot of years.

Hey, I'm not leaving on deployment in May. I will be home for the summer so get that 91 put together so we can hit Walker.....and the Elbe campout is coming up the second weekend in May.