I am having some problems with my lift. I bought a 4.5 inch rough country lift for my cherokee. Everything went well except for the transfer case drop. I followed the instructions given to me by rough country and it told me to do a jam nut procedure to remove the stud. I did that but it removed a few threads off of the stud so putting 2 nuts on is impossible. so instead I used a coupling nut to extend the stud which worked but when I put the new longer bolt on it stripped the threading in the frame. I have no idea what to do I cannot leave it like this. I was told I cannot weld anything to the frame or it will ruin the integrety of the truck. please help!!

 

Weld a nut to the stud and back it out. If you broke the weld nuts off you will have to create an access hole to fix. you can weld to the unibody, just remember it is thin metal.

 

I have to go through this soon, and I just figured I would make and access hole to install a new bolt and nut,it seems to me to be the safest way. I can always repair the frame rail.

 

that is why i bought rustys transfer case drop cross member

 

If I were to make an access hole how would you cut one?

 

i woud use a cutoff wheel or small grinder.

 

o right i guess a cutoff wheel would make sense, It would be relatively quick. Wouldn't it ruin the integrity of the vehicle.

 

Where did you get the cross member? can you send me a link?

 

Before you go making large holes in the frame, if you can weld, just weld a 1/4 plate to the frame. Much less traumatic. If you can do this, you have some options. drill a hole for the bolt to pass through on one side and tap threads into the other. Drill the first hole and use a crush nut on both thicknesses of metal. Either way, you will not be cutting up the frame.

 

I am not going to cut a 4" hole.just large enough to get a bolt in there and then repair the frame. My last 89 did not even have this problem,both bolts were open for easy removal,so I do not think you will compromise the integrity much.

 

I managed to weld a nut on mine and back the stud out. drill and retap the weld nut to 7/16, re-install larger bolts

 

i had the same issue with my lift. i actually ran my drop with only one bolt holding it up on each side for two weeks. then i got time and then the knowledge from cf. go to lowes and get a small torch setup (15 bucks) and then a set of the biggest vise grips you can find in there. and some pb blaster. after i put a lot pb blaster and a lot of heat and i mean a lot, i had to use a cheater bar to close the vise grips on the stud. then back them out like a normal bolt. i would deffinetly try this before cutting into your unibody

Good Luck

 

I did close to the same thing, but instead of vise grips, they wouldn't hold on, I used a dremel to shave down the sides of the bolt so I could get a socket on it. but yea, before you start any work on your jeep always hit every nut and bolt with BP blaster, liquid wrench or WD40.

 

Thanks, I actually went with the approach that involved me cutting into the frame and putting in my own bolts. I know someone with a welding license that will seat the bolts in and close up the frame.