The EASY Way to Remove Broken Upper Rear Shock Bolts from a Wrangler TJ Project 2004 Jeep TJ
September 16, 2017
Learn the easiest method to remove broken rear shock bolts from a Jeep Wrangler TJ using basic tools for a hassle-free repair.
Quick Look
- 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:
- 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:
- 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:
- 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:
- 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:
- Here's my video on removing the TJ gas tank...again, an easy task with the right approach!
- Here's the Bostitch Palm Nailer that I tried and found no value in for this project:
- Here's the Bostitch Palm Nailer that I tried and found no value in for this project:
- Here's the Bostitch Palm Nailer that I tried and found no value in for this project:
- Some helpful O3D Jeeps links for you:
- Some helpful O3D Jeeps links for you:
- Some helpful O3D Jeeps links for you:
Overview
Dealing with broken upper rear shock bolts on a Jeep Wrangler TJ can be a frustrating experience for any owner. If you've found yourself in this situation, you're not alone. This problem is common enough that many Jeep enthusiasts have sought the best way to tackle it. Fortunately, after extensive research and experimentation, I discovered an easy and effective method that requires minimal tools, making this repair achievable for anyone willing to roll up their sleeves.
What This Covers
This tutorial will walk you through the step-by-step process of removing broken shock bolts from your TJ. We will discuss the necessary tools, preparation, and techniques to ensure a smooth experience on this often-dreaded task.
Step-by-Step Breakdown
- Preparation: Begin by safely lifting the rear end of your Jeep. Remove the fuel tank if it obstructs access — this will make the task significantly easier.
- Gather Your Tools: For this process, you'll need a Dremel rotary tool with a 90-degree attachment, cutting wheels, a punch set, and a hammer. These tools will allow you to reach and cut the stubborn bolts effectively.
- Access the Bolts: With your Jeep securely lifted and the fuel tank removed, locate the broken bolts. These are usually tack-welded in place, which creates an added challenge.
- Cutting the Bolts: Use the Dremel with the right-angle attachment to carefully cut through the bolts. Angle the tool to maximize access to the bolt heads while minimizing the risk of damaging the surrounding frame.
- Removing the Bolt Stubs: After cutting, use a punch to knock out any remaining bolt materials. This is a critical step since you want a clean frame for reinstallation.
Helpful Tips
- Be patient and take your time with the cutting process; rushing can lead to mistakes.
- Use cutting wheels that are designed for metal to ensure a clean cut.
- After the bolts are removed, it’s a good idea to apply some touch-up paint to prevent rust on exposed metal.
- If you're upgrading your shocks or lifting your Jeep, anticipate this issue — having the right tools on hand is essential.
Key Takeaways
Successfully removing broken shock bolts from your Jeep Wrangler TJ doesn’t require expensive or complicated tools. With a Dremel, a few attachments, and a straightforward technique, you can tackle this project and get back to enjoying your off-road adventures. Always remember to remove the fuel tank for better access and to take your time during the cutting process. This method not only saves time but also prevents damage to your vehicle. Happy wrenching!