Topic: what to do

[paulc]

  I tried to install a transfer case drop kit one bolt out of the six out the cross member came out leaving 5 loose unable to come out leaving the cross member to bounce around what should i do to put new bolts in cut old ones out and cut holes in frame to be able to drop bolt threw in frame to hold to tighten any ideas would be a great help
                                                                                  thanks paul

[gomi]

hmm, I'm trying to understand as I have also lowered my transfer case, but I can't figure out what happened to you. Do you mean that one of the bolts out of the six holding your skid plate broke? What year is your jeep?

[Jeffy]

Hmm, why are you (paulc) clicking 'Report' on this thread?   

As for the problem, it's going to be a PITA to remove.  Your best bet is to cut the head off then try to weld the nut back onto the frame.  Then use penetrating oil and take the bolt out.

[paulc]

well trying to lower the transfer case the bolts that hold the cross member on wont come off they are all just spinning except for 1 that will come out.  the bolt is spinning and there must be a nut inside the frame that at one time was im guessing was welded to the in side of the frame broke loose causing the bolt to spin not allowing it to come out  so if i cut the head of the bolt of all the ones spinning how do i bolt the cross member back up because i cant put a nut inside the frame because its in closed unless i cut holes in the frame any help how to fix this problem will be very appreciated

[Jeffy]

You grab the stub of the bolt then pull it so it sits where it should then zap it with a welder from the bottom of the frame.  If you have to drill some holes around the opening where the bolt is sticking through then weld through those holes.  You need to secure the nut and if you can weld all the way around so the nut is stuck to the frame.

Like I said it's a PITA to do.  There is no easy out for this.

[paulc]

you cant get to the nut its inside the frame the bolts run threw the cross member threw the frame and the nut sits on the frame inside i was thinking of drilling holes threw the frame next to each bolt  or cutting holes with torch in frame so if i cut head of bolt of the bolt i could push it into frame.  the holes i cut or drill into the frame drop a bolt down threw the frame and cross member ant put a nut on iti was just hoping there would be an easyer way

[Jeffy]

you cant get to the nut its inside the frame the bolts run threw the cross member threw the frame and the nut sits on the frame inside i was thinking of drilling holes threw the frame next to each bolt  or cutting holes with torch in frame so if i cut head of bolt of the bolt i could push it into frame.  the holes i cut or drill into the frame drop a bolt down threw the frame and cross member ant put a nut on iti was just hoping there would be an easyer way

Yes, I know the nut is inside the frame.  You're making this a lot more complicated then it has to be.

Cutting into the frame is not the answer.  Like I said, you need to cut the head of the bolt off so you can get the skid plate off.  Now you are left with the shaft of the bolt stuck on the nut that is now floating around inside your frame.  Grab the bolt and pull it down and see if you can weld the nut to the bottom of the frame from under the Jeep.  If not you will need to drill some small holes near the opening so you can weld the nut back to the frame, from the underside.

[Bounty Hunter]

Jeffy is saying to drill several small holes around the broken bolt, on the bottom side of the frame.  Then weld upside down to get the nut inside the frame attached to the frame.  The more weld the better.

The heat from the welding will help the stud come out of the nut once the nut is secure to the frame again.

[oldjeep]

Jeffys way will work as long as the bottom of the frame is not too rotted out and the busted bolt pieces actually want to come out of the welded nuts. 

The way I've done it on really bad frames is to cut a piece of 1/4" bar stock, drill for the skidplate bolts and weld the nuts to that.  Then use a hole saw on the bottom of the frame to remove the old nuts/bolts.  Then weld the bar stock to the bottom of the frame with the nuts protruding up into the frame.

[aw12345]

They are nut serts and not all that hard to replace to get the bolts out either cut them or tack weld the nutsert to the frame

[neale_rs]

If you don't know how to weld then you could

1) remove old nuts with hole saw
2) lift body off frame
3) drill holes in the top of the frame and drop in long bolts
4) insert crush sleeves from the bottom (make them exactly the right length, flush wit bottom of frame, and make sure they fit snug in the hole saw holes)
5) bolt up with nuts

The welding fixes are better though, so please consider them first.

[oldjeep]

If you don't know how to weld then you could

1) remove old nuts with hole saw
2) lift body off frame
3) drill holes in the top of the frame and drop in long bolts
4) insert crush sleeves from the bottom (make them exactly the right length, flush wit bottom of frame, and make sure they fit snug in the hole saw holes)
5) bolt up with nuts

The welding fixes are better though, so please consider them first.

If you go that route, why go through all the trouble of taking the body off?  Just put the bolts up from the bottom and put the nuts on top the frame.

[neale_rs]

Well, he would still need room to drill the holes in the top of the frame.  I guess he could use a very long drill too.

[paulc]

 i like the idea of getting a long drill bit and drilling up threw the frame and putting long bolt all the way threw i have a body lift to witch will make that a little easier
                                                                                               thanks for every ones help

[oldjeep]

i like the idea of getting a long drill bit and drilling up threw the frame and putting long bolt all the way threw i have a body lift to witch will make that a little easier
                                                                                               thanks for every ones help

Shouldn't need anything special.  Normal 1/2" bits are 4.5" long, unless you are buying jobber bits.