Friday, September 15, 2017

The EASY Way to Remove Broken Upper Rear Shock Bolts from a Wrangler TJ Project 2004 Jeep TJ

[youtube https://www.youtube.com/watch?v=KgrNCt-hRTw&w=640&h=360]

I quickly realized that dealing with broken upper rear shock bolts was something that most TJ owners are going to have to deal with. I was glad I was not alone. Internet searches revealed tons of people asking the same question as I: "How to remove broken shock bolts on a TJ"! Sometimes you can't put enough PB Blaster on these things to get them to break free without snapping!

I read all of the tips and advice, watched a bunch of videos... and tried a lot of things. This video, however, demonstrates what I found to be the absolute EASIEST way to get those pesky bolts out with a minimal expense. You don't need a huge air compressor and an air chisel. You don't need a special little palm hammer. With a Dremel and a single punch and hammer, you can knock this out! (Pun intended.)

Most people probably have a Dremel, but you may or may not have the 90 degree adapter. Here's a list of the products I used to make this simple job happen:

Dremel 3000: http://amzn.to/2xFYi09

Dremel 575 Right Angle Attachment: http://amzn.to/2juXDrU

Dremel EZ456 1-1/2-Inch EZ Lock Wheels: http://amzn.to/2x2YbLb

Stanley FMHT75077 FatMax Punch Set: http://amzn.to/2x8SMld

2-Pound Engineer Hammer: HF or http://amzn.to/2x8rkUu

Here's my video on removing the TJ gas tank...again, an easy task with the right approach!
https://www.youtube.com/watch?v=PhaKH9cuz6M

Here's the Bostitch Palm Nailer that I tried and found no value in for this project:

BOSTITCH PN50 Mini Impact Nailer: http://amzn.to/2whnYjj


And finally, here's the air hammer and chisel bit set I tried. Again... I found it not necessary for this project: Ingersoll Rand Air Hammer 114GQC: http://amzn.to/2y4xWkj

https://o3djeeps.com | OVERCLOCK3D Jeeps | I am cpo.

5 comments:

  1. Great video for tj owners 👍🏼

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  2. You're right. The XJ Cherokee nuts are easy to knock off with an air chisel. TJ Wrangler nuts are a no-go. Good job!

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  3. Wow great vid CPO! By far the best on youtube for this job. Perfect angles to see exactly whats going on.

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  4. My fix for the issue was to install a nut plate. I was able to get the old nuts out easier than you had (I have 1" body lift which gave me enough for a chisel to use through the wheel well).
    My nut plate is basically 2 nuts also spot welded onto a 1.5" wide 1/4" plate. The plate has holes drilled through as well. I used new bolts (female hex) and matching nuts. The plate is upside down and is long enough to be held outside the frame to secure the bolts in the shocks ball pin mount.
    You have to use female hex head bolts due to the frame location relative to the outside bolt. A regular hex head can work, but your socket won't fit the bolt head with it being so close to the frame.

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