Installing my new IRO lift, got the front all done, moving to the rear. All four spring bolts came out about a half inch or better, then the metal bushing seized on them to the point that when I continue loosening them the bushing is bending the outward side of the spring pocket as it tries to come out. Yes it was soaked in WD40. Question is what now, not sure that the bolt has released from the nut all the way so cutting could open a whole new can of worms, as in how to get the rest of the bolt out of the nut. The last one I did all the bolts came right out, not so lucky this time!

Know anybody with a set of torches? Get em cherry red and they'll come out

Turn the sleeve with the bolt until the slit is so you can see it, pound a big flathead in there and start prying until you can wedge it in good. Then hold that real tight so the sleeve doesn't move, spray some pb blast in there and start cranking on the bolt until it's free. If that doesn't work, continue to pry open the bushing sleeve and keep trying.

I had this same problem on one side of my rear leaf pocket. I had to use my 4.5 inch grinder/cut off wheel to get up in there and cut the leaf off the eye then was able to cut the eye/bushing in half and get it out of the way to get the rest of the bolt out.

If you look up my build there are photos of it and you will see what I am talking about. It did not take me long to do the removal. Maybe 30 minutes.

Saved you a little trouble. Here are the pics.

Appreciate the help guys. Ended up having to cut three out of the four with the angle grinder. Problem is now two things, now I dont have leaf spring bolts because they dont come in the kit, and one of the nuts in the frame has semi-stripped threads from the bolt just turning and not moving. I have parts jeeps so I can scavenge some bolts, and I guess I will have to cut open and remove the welded nut. What I will say is its a good thing I have done this before, the IRO "instruction" manual really isnt, .....pretty vague honestly.

Sounds like you had your work "cut" out for you. Bad pun, I know. At least the hard part is over. Seems like it is easier putting it all back together with new parts.

Definitely at least cleaner, all new stuff including the front and rear ends that I swapped over from my other XJ with 4:56 gears and lockers front and back. While they were out I cleaned them and painted them too, should look like a whole new jeep underneath now!

do yourself a favor use an actual rust penetrant next time wd40 is a water displacer use pb blast or something

Kano laboratory makes an awesome penetrating lubricant. It puts pb blaster to shame. I use it all the time and bolts come out super easy.

mix acetone and atf in a 1:1 ratio, best penetrant you will ever use period!

I had one when I did my son's lift. Heated the snot out of it, burning part of the bushing in process. Thought someone would maybe want/need some stock replacement parts, they still sit behind garage, lol. Maybe yard art?

Maybe I didn't use right ratio with atf/acetone, but wasn't impressed, plus the acetone evaps off , plus no good way to spray (suggestions?)

a regular squirt bottle or buy a pressurized spray can