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Old 09-21-2010, 11:34 AM   #1 (permalink)
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Front Track Bar Bolt Rusted In - 98TJ

My lower front track bar bolt is rusted in. Anyone have any advice on getting that stuck bastard out? As you know, the nut is burried up under and behind the bracket, so you can't easily get to it.

I have already striped out the Torq headed bolt.

My plan is to weld a 5/8" nut onto the end of the Torq bolt and try it again.

Any other suggestions?

Thanks for any help,
NIB
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Old 09-21-2010, 11:52 AM   #2 (permalink)
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Weld a 5/8" nut onto the end of the torx bolt and try it again.

I've had success with cutting the edges off the bolt head to where you can fit a wrench on it.

Or cut the entire bolt head off relieving the pressure on the bracket. Then cut the bolt inside the bracket to let the nut plate fall out.

Or cut the whole damn bracket off and replace it with something beefy.
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Old 09-21-2010, 12:17 PM   #3 (permalink)
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Originally Posted by NIB-98TJ View Post
My lower front track bar bolt is rusted in. Anyone have any advice on getting that stuck bastard out? As you know, the nut is burried up under and behind the bracket, so you can't easily get to it.

I have already striped out the Torq headed bolt.

My plan is to weld a 5/8" nut onto the end of the Torq bolt and try it again.

Any other suggestions?

Thanks for any help,
NIB
Carefully grind off the head. Pry the front of the bracket forward and then move the trackbar forward. Use a cut off disc on a grinder to slice the bolt off behind the trackbar bushing without hurting the bushing.

I've done it that way several times because the bolt rusted into the bushing sleeve.
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Old 09-21-2010, 01:19 PM   #4 (permalink)
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Thank you Sirs for your helpfull suggestions. I'm sure that one of them will work for me. I was tired the other night when I ran into the problem and didn't really see anyway around cutting part of the bracket off. The OEM track bar is long gone and whats on the now now is an RE adjustable track bar.

Thanks again for y'alls help.

NIB
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Old 09-21-2010, 01:27 PM   #5 (permalink)
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usually if you weld a nut on it, you can take advantage of the heat from welding to crank it out.

if it's seized in the sleeve, you are stuck with cutting the bolt on either side of the bushing....which is a pain in the ass....
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Old 04-11-2012, 05:15 PM   #6 (permalink)
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Old thread I know, but I just tried the welded 5/8" nut without success. Going to try the other method next. Thanks all for the help.

NIB
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Old 04-11-2012, 05:19 PM   #7 (permalink)
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Old thread I know, but I just tried the welded 5/8" nut without success. Going to try the other method next. Thanks all for the help.

NIB
You're going to try the next step in two more years?
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Old 04-11-2012, 08:20 PM   #8 (permalink)
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You're going to try the next step in two more years?
Hey, I'm slow, but I am steady.

Well, method #2 worked, but it was a real PITA.

I knew that bolt was rusted in a while back, but I just kept putting off doing anything about it. But then I ripped the upper trackbar mount off the frame Saturday, so I figured I would fix both ends while I was at it.

Thanks again for all the suggestions.

NIB
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Old 04-13-2012, 07:58 AM   #9 (permalink)
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Rusted Bolt, solution.

I had the exact same thing happen to me. Fortunately, I had the axle out so access was not a problem. I tried all of the "easy" methods before I resorted to cutting the "box" with a plasma and then welding in a new mounting box. I took the bolt and offending bushing sleeve and used a BFD in an unsuccessful attempt to get the bolt out of the bushing sleeve. I only hope that my welds hold as good as that rust did. Good luck.
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Old 04-13-2012, 07:59 AM   #10 (permalink)
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BFH not BFD

Stupid fingers!

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I had the exact same thing happen to me. Fortunately, I had the axle out so access was not a problem. I tried all of the "easy" methods before I resorted to cutting the "box" with a plasma and then welding in a new mounting box. I took the bolt and offending bushing sleeve and used a BFD in an unsuccessful attempt to get the bolt out of the bushing sleeve. I only hope that my welds hold as good as that rust did. Good luck.
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Old 04-13-2012, 08:07 AM   #11 (permalink)
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A trick that I learned from the in-law, and it works great. Heat the bolt up with a torch, and then hold a candle to it. The heat will melt the candle, and pull the wax in. Same concept as flux when soldiering.

Last edited by mwstudt; 04-13-2012 at 08:07 AM.
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Old 04-13-2012, 08:19 AM   #12 (permalink)
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I took the bolt and offending bushing sleeve and used a BFD in an unsuccessful attempt to get the bolt out of the bushing sleeve.
After I cut it all out, I tried the same thing with the sleave on a vice. I beat the crap out of the bolt with a punch and chiesel, but It would not budge. Luckily I had some 3/4"OD with a 3/8"Hole DOM laying around so I could make another sleave. Mine is not factory, it is the RE trackbar.

Glad I finally got the dang thing fixed. Now I have to weld the trackbar frame bracket back onto the frame. I ripped it off last weekend.

NIB
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Old 04-13-2012, 04:18 PM   #13 (permalink)
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this happened to me, cut the bolt right out of the track bar with my torches i was replacing the track bar any way
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