I've tried a pipe wrench, vise grips, soaking it in pb blaster. Nothing works.
The only thing I haven't tried is heat because my torch nozzle broke and I haven't had a chance to get a new one. But either way the bolt sheared off almost flush with the mount. I opened up the unibody channel behind the bumper but not sure what to do now.
I also tried hitting it with a hammer an chisel to break the welded but free and tried drilling it out, neither worked only burned up the drill bit.
Any help would be greatly appreciated at this point because I'm outta options

 

Here's the picture from inside the unibody

 

Hm that looks like an interesting one. I see you already tried to grind/file some flat spots on there. My next move would be to grind/file a bit more to get the best bite possible with vice grips and use your torch to heat that sucker up.

I believe those are 10.9 grade bolts so they're pretty tough to drill through. I've had some luck using left hand drill bits to get bolts out but I don't think it will work unless you get some high quality ones that will cut through that steel.

 

cut a hole in the floor & take it from the top. I did it that way first so I could hit it with a torch, but maybe you can sawzall the bolt from above.

 

Drill through the shackle bushing into the seam of the inner sleeve, and fill it with PB Blaster to break up the corrosion inside. You'll need to tack a head back on that bolt somehow.

Otherwise go through the floor board as described above

 

I'm gonna try an put some more flat spots on it and hit it with a torch after I get home from work. I was trying to avoid cutting a hole in the floor but if that's what it comes to I'm gonna have to.
I would tack a nut on what's left but I don't have access to a welder unfortunately

 

Sounds like a good time to go to some no lift shackle relocation boxes..

 

I had the same thing happen. Don't know if it will work for you, but this is what I did.
https://www.cherokeeforum.com/f46/in...24675/index10/

 

Don't you still need that bolt hole? It has to come out regardless.

 

yup

 

get the next size bigger nut put over it and weld it then use a wrench to take it out the heat from welding will break it loose

 

cut a slot in it... then heat it and use a screw driver to remove it

 

I'm gonna try griding a slot it what I have left exposed, heating it, and trying a screw driver or somthin.
If that doesn't work I'll try welding a nut on to it if I can borrow a welder off of someone

But either way I was planning on doing no lift shackle relocation boxes from Hd off-road I think because my angles probably gonna be off