Broken nut on shackle on XJ

93redzj

93redzj

Well-Known Member
Joined
Aug 29, 2005
Location
Albemarle
so I was installing my RC 4.5” lift today, front sucked but got it finished, moved to rear, was attempted to loosen and remove the bolt that holds the shackle in place so that I can install the extended shackles, and the welded nut broke loose and now the entire bolt/nut just turn....we attempted to get to the back side of this nut but no dice, who has encountered and mastered this obstacle before?
 

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Open up a window in the frame to access it, cut the bolt off with a cutting device, install new bolt and nut, weld nut to a plate and weld plate to frame or size it such that it can't rotate.
 
if I am understanding, the bolt that goes through the pocket in the body, is seized into the bushing....been there.
1. Remove the leaf spring from the shackle (should be able to persuade it out with a BFH)
2. Fire up the angle grinder, even a small 4" wheel will get you past the bolt centerline. Cut close the the bolt head, but through the body of the shackle. Cut half way through, rotate bolt, cut, rotate, cut, etc. two or three rounds and you will be free of the bolt head.
3. Should have enough room to rock the shackle out with what remains of the stuck bolt.

Just noticed you also broke the nut in the frame, should work if you make the same cuts on both sides of the shackle. Leave enough stub to tack the nut back, and vice grip out the remainder of the bolt. Chase it with a tap and you are back in business.
 

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I had the same issue at the front of the spring, I heated the bushing, and tried to cut a bunch of the bushing away. I recommend a mask/face shield and a set of welding gloves. Grinding wheels and rubber suck for sooo many reasons.
 

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The bolt isn’t seized in the bushing itself of the shackle. If that’s what you’re referring Shelby? But rather the part inside the frame that the bolt threads into that is supposed to be welded in place has broke loose and now the entire bolt just turns.

Kelley, could we continue to cut the top part of that frame section to access bolt? In picture 2 I believe, we did attempt to cut the bolt with a sawzall but that didn’t work at all
 
if you cut the shackle at both ends, you can get the bolt head off, the shackle out, and have enough stub of bolt, to hold onto the welded nut and tack it in place.
The heat of welding will break the bolt/stud free. Then you can proper weld the nut in place from the shackle pocket side.
 
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You could go through the top of the frame, I'm assuming that's top looking down from in side of the cargo area. Just weld up your opening when you're finished. You could like @shelby27604 suggested welding the nut place in from the shackle side outside the frame, easier to get the welding torch in. Drill a few holes to rosette weld to the plate and you'll be good to go. Of course, once you have the bolt out and the new one in, your good even without welding it in.. assuming you don't need to change the shackle in the future.
 
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