So I tackled the rear springs today. I meant to do the front springs as well, but time wasn't on my side and I was only able to get the rear springs replaced; somehow, even though this truck was originally from New Jersey, I was able to get all six of the bolts out without stripping or destroying any of them. Probably helped that I'd been soaking them for weeks. However my dumb *** forgot my new rear shackles at home so the stockers are still on there.

I think I might need some new bump stops as well...these might be past their prime....thoughts:


I did run into a real problem though. Both my upper shock mounts are toast. Driver's side has a sheared bolt and a bolt replaced by someone at some point sticking through the mount. However, the passenger side is really wrecked. Someone had tack welded some bolts up there and they broke off (actually this morning, on the way over to the shop and the shock was just sitting there...I thought I smelled something burning...)

You can see the melted cover


So here is my passenger side upper shock mount; what can I do? Can I have a plate welded up there?


Furthermore, the passenger side front mount has some bad rust issues in the floorboard...what's the best way to go about repairing this?


You can see me poking the exposed inside insulation


I had to use a bottle jack to support the mount when I was removing the front bolt because of all the flex


Annnnd, to top it all off, I tossed the bottom shock mount nuts into the waste metal bin and they are all the way down on the bottom...anyone know what size they are?

I'm going to have to change my name to Mr. Bouncy Waggie until I've got a good solution...

Thanks for your help guys!

-Matt

 

Look for another Jeep.

 

thanks for your input.

Anyone have anything that's actually useful?

 

That is the best advice. Unless you can do a lot of welding to replace the metal, it would be cheaper to buy another and transfer what's good then part this one out.

 

Really? I've seen posts on here where folks have replaced entire floor pans. I've got one 6''x6'' area where it came through, I can't imagine that warrants buying a new Jeep.

 

Floor pans aren't critical structure like the floor right near the spring hanger.

 

Oh my. That jeep under carriage looks like it's been sittin at the bottom of a salty ocean. I can't imagine what the inside of the frame looks like. I'd look for another jeep. Btw, I've replace the entire floor pans of my jeep and the rust was not near as bad as yours.

 

I know it's hard to hear that but it's the truth. Looks like you just put new exhaust, fuel filter, etc on it too.

 

That's structural, and not easy to fix. If you have the time and know-how to work with metal, and can weld, go for it.

Otherwise, find a body shop that knows welding. Get a quote. Then decide.

 

^^ Exactly what BlueRidgeMark said. Go to a body shop, get a quote, call some people ask if they anyone that would do taht type of work. Then decide the poison.

I bid you well in your journey.

 

Bump stops are nothing.

http://www.partstrain.com/store/deta...?location=Rear

As far as the upper shock bolts they bust all the time. You just whack them out and with mechanics wire drag a bolt through the whole and nut from the outside. Plenty of info about that. Can't really see in the picture what kind of structural issues you have there so you might have to reinforce that some. Recently found these this is to help with the broke upper shock bolt issue.

http://www.roughcountry.com/jeep-xj-...-nut-1082.html

https://www.youtube.com/watch?v=BWJl...ature=youtu.be

As far as the leaf spring mounts go maybe this?

http://www.synergymfg.com/Synergy-Su...tml#.VJ6ihl4Aw

Had a '96 with very similar issues. Never welded before but was seriously considering trying. Ended up selling the Jeep. But had done some of the leg work already. Good Luck.

 

Thanks for all the input fellas. There are some rust issues, but luckily aside from this one area the rest of the undercarriage is actually in pretty good shape. I'll probably remove the rear carpet and get a better assessment of the situation before search for a new truck though.

I did come across these brackets; they may be a viable option if I can get the floor fixed without too much trouble:

http://www.polyperformance.com/Syner...Hanger-Bracket

Though these may work as well:

http://www.rustysoffroad.com/builder...-brackets.html

 

It's that "C" word, not good...rust kills Jeeps.
Though the good news is with enough time & money you can fix it (or just buy a Corvette with the $$$$$).

 

I think you can get a bunch more use out of the Jeep with some metal work. Cut out all rust. Weld some plates over the upper shock mount holes, predrill them and tack some nuts to the backside to accomodate bar pin eliminators. That forward leaf mount is a little more involved but again, cut out all the rust. Replace the floor pan with correctly cut and bent sheet, fab a bracket out of some angle or flat stock. Use heavier gauge material than the rusted out stuff. Finally paint and/or undercoat the heck out of it. It'll be a project but if you do it yourself and have a welding rig available to you, costs will be minimal.

Good luck

 

Thanks again for the assistance fellas!

Luckily, the undercarriage of the truck *was* coated before so aside from this obviously bad spot and the non-coated areas (axles/etc) it's all in pretty decent shape. I do intend to do a lot of the work myself, I have limited welding experience...and no welder. But I do have experience with metal bending/etc. I figure I can do all the prep work myself and have a mobile welder come by for a couple of hours to pop it together for me.

It's not perfect, but it's mine...and I don't like to lose. So it shall be fixed.