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Broken Shackel Mount (Welding Question)

Old 03-26-2019, 12:25 PM
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Default Broken Shackel Mount (Welding Question)

91 XJ 4.0

I've been putting on a 3 inch rough country lift over the last three weekends, and have learned how to efficiently remove those stuck bushing bolts pretty well (I thought). I had an after market rear shackle lift installed that needed to be removed before I could install some OEM shackles and finally get the new rear leaf springs in. The shackle bolt was incredibly stuck, but after some torching blaster and a huge cheater bar started making some progress. Unfortunatly the bolt ended up snapping when it was about 2 inches out. After some eye balling and wiggling at the shackle I came to the conclusion that the bold was almost out of the threading in the frame, so I have it some good smashes with a hammer to help it wiggle its way out. Long story short I ended up breaking the frame where the shackle bolt threads in. After calling a few shops and realizing it very few would do the work, and the ones that would seemed pretty hesitant I've decided to just fix the thing myself. I know ill need to rip out whats in there, and weld in something new.

Any advice or tricks would be more than welcome, thanks!

Close up of damage

Overall view

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Old 03-26-2019, 02:31 PM
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That shackle looks like it is diagonal instead of square with the frame. Am I looking at it right?
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Old 03-26-2019, 02:33 PM
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Originally Posted by 4.3L XJ View Post
That shackle looks like it is diagonal instead of square with the frame. Am I looking at it right?

yessir, that is a product of the hammering, its pretty much just hanging loose at this point.
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Old 03-26-2019, 03:54 PM
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Do you have a MIG available?
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Old 03-26-2019, 04:02 PM
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Originally Posted by 4.3L XJ View Post
Do you have a MIG available?
I've got an electric welder, from what I can tell it should do the trick. My main concern is finding the safest way to weld to that frame, if a bigger hole would be better than a smaller hole, should I usr a nut wended to the patch or Tap the steel i weld in, what kind of steel to use etc.
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Old 03-26-2019, 04:45 PM
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If you are using a stick welder, I wouldn't recommend it unless you are very good at it and using something like jet rod (8024). It is too easy to burn through that thin metal we have
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Old 03-26-2019, 05:44 PM
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Judging from the amount of rust in the pics, and the condition of the metal, I'd say it's time for some shackle relocation boxes....lift or no-lift style, either will work

This is what I did when I had a problem with mine....https://www.naxja.org/forum/showthread.php?t=1123584


I do wish I had moved the shackle bolt forward forward tho, as then it would have modified my shackle angle as well.


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Old 03-26-2019, 05:48 PM
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that was my next suggestion. The only option I could see with the thickness of metal there is acetylene gas welding
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Old 03-26-2019, 05:51 PM
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Originally Posted by 4.3L XJ View Post
that was my next suggestion. The only option I could see with the thickness of metal there is acetylene gas welding
I used a mig....I would not use an oxy-ace setup there............driver side is too close to the fuel fill line for a flame to be in that area.........at least for my likes.
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Old 03-26-2019, 06:00 PM
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This looks like it might be the best solution for me, nice work!
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