xj^REMY
NAXJA Forum User
- Location
- Connecticut
So, got around to installing the set of Bilstein 5100's I've had for over a year. Bought from a forum user who had them for a ZJ w/4.5" lift, new & never installed. The collapsed/extended measurements fit what I needed, & was a deal I couldn't pass up. I wanted to overhaul the rear suspension, before I put them in, & finally got all the parts & ambition to get it all done.
When I go to take off the old shocks, driver side comes off (& I realize this is a welded in 5/8's bolt, that the PO did), then the passenger side axle stud immediately snapped off, where the threads meet the non-threaded part.
I'm thinking to drill it out to accept a 5/8's bolt (like the driver side) but before I started all that, for some reason, I decided to mount the shock on the driver side, & come to find out the shock eye has a metal sleeve... ok... press it out with the bench vise? Nope, would not budge. Did a little research, & came across a statement made by a Bilstein rep, something to tune of it being difficult to remove with common garage tools, & they have a special tool for installing/removing the bushings/sleeves... blah.. blah.. Also, find out the only difference between the XJ & ZJ applications, is the sleeve.
At this point, everything else is done, but 1) I've been at this overhaul on the rockee for longer than I wanted to 2) I've got a broken shock stud 2.a) I drill it out to 5/8's AND keep trying to get the sleeve out of the shock eye, possibly damaging the shock and/or the bushing, OR 3) leave the shock alone, & tackle my first official welding project on the rig by modifying the axle mounts.
...I opted for option 3
^240V, .030 fluxcore
Figured I'd mount it like it's mounted a ZJ. The bolt needed to fit the shock eye was a 15/32. Local Home Depot didn't have it, nor across the street at Lowes. F THIS! Went to the junk yard, waited 5 minutes & paid $5 for the bolts off a ZJ. Thought about going to buy some material, but then I realized I've got something I could use...
Cut it up...
Drilled it out to 5/8's...
Bent, trimmed & drilled the 15/32 holes...
Trimmed the studs...
Burned it in...
What I ended up with...
I am also going to add some tabs on the sides of the bracket to the axle bracket for bracing. I was trying to get better pictures of the welds, but the camera sucks. I'd love to hear feedback from more experienced welders. I'm 75% confident I got good penetration, but it was hard to tell. For those that are familiar with the Hobart 190, I had the voltage at 6, wire speed at 3-4.
I want to run with this until I swap this axle out, or until it breaks. I have another 8.25 I'm freshening up, & will do something different with the mounting on that one. For now, I have a little more welding experience & I got my shocks mounted.
When I go to take off the old shocks, driver side comes off (& I realize this is a welded in 5/8's bolt, that the PO did), then the passenger side axle stud immediately snapped off, where the threads meet the non-threaded part.
I'm thinking to drill it out to accept a 5/8's bolt (like the driver side) but before I started all that, for some reason, I decided to mount the shock on the driver side, & come to find out the shock eye has a metal sleeve... ok... press it out with the bench vise? Nope, would not budge. Did a little research, & came across a statement made by a Bilstein rep, something to tune of it being difficult to remove with common garage tools, & they have a special tool for installing/removing the bushings/sleeves... blah.. blah.. Also, find out the only difference between the XJ & ZJ applications, is the sleeve.
At this point, everything else is done, but 1) I've been at this overhaul on the rockee for longer than I wanted to 2) I've got a broken shock stud 2.a) I drill it out to 5/8's AND keep trying to get the sleeve out of the shock eye, possibly damaging the shock and/or the bushing, OR 3) leave the shock alone, & tackle my first official welding project on the rig by modifying the axle mounts.
...I opted for option 3
![eznr.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg35%2F8572%2Feznr.jpg&hash=51b1641be52baf9ad22ad783ee4a14d1)
^240V, .030 fluxcore
Figured I'd mount it like it's mounted a ZJ. The bolt needed to fit the shock eye was a 15/32. Local Home Depot didn't have it, nor across the street at Lowes. F THIS! Went to the junk yard, waited 5 minutes & paid $5 for the bolts off a ZJ. Thought about going to buy some material, but then I realized I've got something I could use...
![l3p2.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg35%2F5804%2Fl3p2.jpg&hash=b773e351314cbd445fed5b6427ec617d)
Cut it up...
![cy37.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg13%2F412%2Fcy37.jpg&hash=20fbf6c6376ac927536cf117ae9dbd1e)
Drilled it out to 5/8's...
![aj4w.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg834%2F6900%2Faj4w.jpg&hash=cd651d771388febea47b983d63eb127e)
![uisp.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg842%2F84%2Fuisp.jpg&hash=12d3b506ae40e65ccef91693bf8cf827)
![yt3.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg849%2F3170%2Fyt3.jpg&hash=71c35ee3a6e426f415cd5cd8ec57a1f5)
Bent, trimmed & drilled the 15/32 holes...
![u49z.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg801%2F8314%2Fu49z.jpg&hash=5082a76fb3d303fa6a6fa78b5fe69fed)
Trimmed the studs...
![3awd.jpg](/proxy.php?image=http%3A%2F%2Fimg834.imageshack.us%2Fimg834%2F6185%2F3awd.jpg&hash=8d7a0809d8c803a20f3972e97e642e48)
![5sxy.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg94%2F1707%2F5sxy.jpg&hash=6e7c6043bd47f5c50dd5210bdc9c8319)
Burned it in...
![3aqf.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg706%2F8352%2F3aqf.jpg&hash=7013fca68ae3cc3c0b76a90c512bb125)
![fjzv.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg33%2F8985%2Ffjzv.jpg&hash=c4b18febf7696194411166a9207b649c)
![qcod.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg822%2F6973%2Fqcod.jpg&hash=40a3596b2a4ffe88407d46e33561468d)
What I ended up with...
![auqa.jpg](/proxy.php?image=http%3A%2F%2Fimageshack.us%2Fa%2Fimg89%2F9499%2Fauqa.jpg&hash=350d956bc1458680ba279efac2760913)
I am also going to add some tabs on the sides of the bracket to the axle bracket for bracing. I was trying to get better pictures of the welds, but the camera sucks. I'd love to hear feedback from more experienced welders. I'm 75% confident I got good penetration, but it was hard to tell. For those that are familiar with the Hobart 190, I had the voltage at 6, wire speed at 3-4.
I want to run with this until I swap this axle out, or until it breaks. I have another 8.25 I'm freshening up, & will do something different with the mounting on that one. For now, I have a little more welding experience & I got my shocks mounted.