I know I'm probably going to get some flames for being a newbie, but keep it nice...
Now, my question is: I'm installing a Rubicon Express 4.5" lift on my 88 XJ and I cannot for the life of me get the rear shackle bolt out. Does anyone have a suggestion or trick, or even a way to cut the sucka out of there? Any help would be greatly appreciated, and the quicker the better!

hammer and punch

The problem with that is the bolt goes into a nut that is weleded inside the "frame" that we can't get to. This damn bolt is just starting to stip, and won't turn any more. HELP!!!!! <IMG SRC="smilies/beer.gif" border="0">

This is a common problem. Unfortunately there isn't much you can do other than drill a small hole in the underside in order to get a wrench on it. It is a real PITA, trust me. It is just tack welded to the frame and they break all the time. Good luck.

Thanks, that's exactly the kind of help I was looking for!!! You rock!!! Now, where exactly is this hole, the bottom of the "frame?" also, how big? Thanks ever so much!! You just saved us at least an hour!Thanks, that's exactly the kind of help I was looking for!!! You rock!!! Now, where exactly is this hole, the bottom of the "frame?" also, how big? Thanks ever so much!! You just saved us at least an hour! <IMG SRC="smilies/smile.gif" border="0">

Come on people, I know others have had this problem right? Step up folks! Where do I drill and how big of a hole?!??! <IMG SRC="smilies/smokin.gif" border="0">

I put an impact on mine and let it do the work. Mine came out.

Use a Sawzall (or similar, non-Milwaukee reciprocating saw device).

uh, okay, but then how do I get a new nut on the other side of it?

torch it out and then go with a new shackle and bolt fawk that shit up. <IMG SRC="smilies/roxy.gif" border="0"> <IMG SRC="smilies/smokin.gif" border="0">

Like I asked before, then how do I get a new nut on the back side? The "frame" is in the way! <IMG SRC="smilies/confused.gif" border="0">

Well, if it's like the bolts that are tack welded inside the frame of a CJ (I'm sure it is), you need to cut a hole in the frame inline with where the bolt goes in. Do this on the side of the frame. You'll be able to get a wrench on the nut and you'll also be able to tack weld the nut back into place when you pull the old one out. I have a couple of "extra" holes in my CJ frame because of the very same problem.

I don't really have access to a welder, is it important that I re-tackweld that nut inside the frame? What if I just leave it? <IMG SRC="smilies/question.gif" border="0">

No, you don't have to retack it inside the frame, just leave the access hole there and any time in the future that you need to remove the nut and bolt, you'll just have to put a wrench on it. Just makes it easier down the road if the nut is welded inside the frame.

Thanks for the help!!

Oh nom it gets better:

If you look close that nut is actually in a little pocket in the frame. you vave to cut that pocket open.

I personally suggest you sight into the frame from behind the bumper mounts and use that as a guide to cut down from the inside with a holesaw. Now if you miss a little just break out the grinder and have at it till you can put a wrench on that fawker. You have to be carefull here, it can happen where when the nut busts off of the frame it takes some sheet metal with it leaving a ragged gaping hole. If this is the case you have to weld a nut to a washer and then weld the washer to the frame, it is a huge PITA.

HTH