How to fix broken crossmember/transfer case spacer bolt/studs
 

My repair was on the driver side that had the stud but when doing a tcase drop you have to remove the studs up front on both sides and replace them with longer bolts. That sometimes doesn't happened and they break off at the frame then have to drill out the broken stud for the cossmember when thats done theres just a hole with no threads and nothing to rethread at the frame

Tools Needed: one floor jack and one jack stand, metric set of wrenches and sockets at least 6" extension, knuckle aka u joint 3/8 or 1/2 inch drive, drillpress or power drill with shape drill bits, table vise, needle nose pliers

Attachment 107253

I was lucky to find a "dead bolt" few washers and nuts in the garage for the repair. No need for me to go to the hardware store but the dead bolts come in many sizes to get and anything will work just cut the unneeded length

Removed seat, carpet, crossmember (support your tcase with a jack stand) and when I got the carpet out of the way to work I noticed there is two drain plugs above where the broken stud was drilled out inside the frame (very lucky) if no plugs, this is where you have to cut a hole above your work to get your socket to tightened the dead bolt to the frame.

Attachment 107256

Attachment 107255

Attachment 107254

Recessed a transfer case spacer around 1 inch deep and 1 to 1 1/4 inch wide depending on the size for the dead bolt. So the spacer to be flushed on the frame and so it won't be notable.

Attachment 107257

Get the recessed spacer facing up, washer, nut and your wrench tightened the spacer to the frame

Attachment 107260
Attachment 107261

Add crossmember, locking washer with nut and other bolts to your crossmember

Attachment 107263

This will work on any 4 crossmember bolts just have to get above it, not recommend cutting/making a hole on the side of the frame and weld a patch up theres fuel/brake lines and a gas tank few feet away from the work but in the cab of the jeep can cover the hole up with carpet haha or can rivet/screw a patch over it then throw the carpet over

Thanks for reading good luck pm any question