Busted Shock Bolt Help

[Fire Ball]

I'm in the process of replacing my shocks on my TJ and I busted off the last bolt on the upper rear. I can't figure out how to get the remaining bolt out. I tried drilling it out but broke my drill bit.


Any suggestions would be appreciated, this is my daily driver and I need it in the morning to got to work.

I don't have a torch but I have just about everything else.

[live24wheel]

Hopefuly you didnt break the bit off in it but if you did you gotta get it out. I actually had all 4 of my rear uppers drilled out. I then used grade 8 bolts and lifted the body off the frame a couple inches so i could get my hand in there to put a nut on it. I drove around for almost 2 months missing a passenger rear shock, after breaking it and destroying the mounts in Mexico! :eek:

[YGOHOME]

could you cut a line accross the face of it using a dremel? you could then try to extract it using a screwdriver... even if you had to cut into someof the surrounding material to get the line cut into the bolt, I'd think that might work.

or drill and tap a new hole(s) so instead of the upper bar pins going this way "-" they'd go this way "|"

or buy another drill bit and keep working on drilling that broken bolt. By the way, it won't hurt to drive with a rear shock unattached for just a couple days until you get it worked out. Just detach it at the bottom so the top isn't flopping around and puncturing the gas tank. ha

p.s. replacement bolt is 8mm diameter thread and 1.25" long. don't forget the washers.

[live24wheel]

could you cut a line accross the face of it using a dremel? you could then try to extract it using a screwdriver... even if you had to cut into someof the surrounding material to get the line cut into the bolt, I'd think that might work.

or drill and tap a new hole(s) so instead of the upper bar pins going this way "-" they'd go this way "|"

or buy another drill bit and keep working on drilling that broken bolt. By the way, it won't hurt to drive with a rear shock unattached for just a couple days until you get it worked out. Just detach it at the bottom so the top isn't flopping around and puncturing the gas tank. ha

p.s. replacement bolt is 8mm and 1.25" long. don't forget the washers.



Or a couple months :D :cool:

[Fire Ball]

I have the shock off as it was the last bolt to take off that broke. It is a #5 bolt so I cant seem to get a drill to bite it. I think I'll try the rotating idea.

Maybe I can use the plasma cutter to blow the whole thing out an just put a nut and washer on the top instead of the welded in nut. Gonna be tough to get to though, might have to raise the body a little. Man this is turning into a nightmare.

[Phx Cobra]

I have had to dremel one out before(when I did my lift).
Just cut a slot across the top, then take it out with a flathead screwdriver.

[Fire Ball]

I can't get to the top and the bottom side is recessed because there are 2 layers of metal and the first layer is enlarged almost like it was counter sunk so the bolt is actually broken off even with the inside layer so it is below the surface about 1/8 inch. I'm starting to make some headway with the drill but is is slooooow going. Don't want to get out the heat yet since I'm afraid is will make the problem even worse. It wouldbe nice if I had some decent drill bits that would actually eat this metel. Guess I'll have to make a tool run ;)

[Fire Ball]

Yeehaaawww Nothng like a drill, an air chisel, and one slashed finger to get the job done. Now all I need to do is replace the bolt and I'm home free. Thanks for the help guys.

[Renob]

Next time use an E-Z Out broken stud extraction tool and penetrating oil. Works every time and is very simple.

[rockr]

and you can always make it to work on 3 shocks:D

[Fire Ball]

I tried the EZ out but was affraid it would break too. It was rustred in there so bad that even after I busted the welded nut out, I still couldn't get the bolt to come out even in the bench vice. This is the problem I have been having since I bought this jeep from Wisconsin. It is totally rusted from one end to the other but luckily no body rust. I just hope the frame doesn't give out.

[Lonnie]

Sounds like you need a case of PB blaster to spray on the bolts before you start to take things apart.

[OlneyJeeps]

diamond drill bit
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=32351

or

reverse bits ...I use smaller one for about 1/4 inch, then bit 1-2 sizes larger (starts to peel a nice shaving, then bites and turns remainder of stud out)

[Fire Ball]

I'm gonna hae to check out the diamond bits.

I use PB or WD40 on everything and let it set for a couple days before taking everything off. Guees I was just too impatient. I got new shox from 4ws and couldn't wait to get them on. Amazing what having the 2 extra inches of travel to go along with the shock spacer lift will do.