Having a problem installing the sway bar disconnects that came with my
Rubiconexpress 3.5 inch lift on my '96 Cherokee XJ. The rest of the
lift went fine, just having trouble figuring out how to remove the
mounting bolt on the axle flange for the sway bar end link since the RE
unit comes with a different bolt that must be installed. It's a torx
head bolt but doesn't unscrew even with a the largest breaker bar I can
find. Tried hammering it out thinking it was press fit but had no luck
with that either.

Anyone have any experience with this that they can share? I tried
searching the groups but wasn't able to find many threads on this
topic.

Thanks,
John

 

John,

There are several things to try to help resolve the situation and you may
have already tried some of them.

Apply a penetrating oil such as PB Blaster several times a day for several
days to a week beforehand.

The assistance of a burley friend on the end of the breaker bar.

Addition of an extender to the breaker bar..... not recommended by the tool
manufacturer but a length of pipe over the handle can greatly increase the
effective length and torque multiplication.

Application of heat to the bolt. The expansion and following contraction
will sometimes break a bolt free.

Cutting-grinding-drilling removal of the old bolt.

Obviously you should start with methods that may inflict the least damage
i.e. don't start with a cutting torch

"John W." <jwagenleitner@gmail.com> wrote in message
news:1138730428.951890.311390@g14g2000cwa.googlegr oups.com...
> Having a problem installing the sway bar disconnects that came with my
> Rubiconexpress 3.5 inch lift on my '96 Cherokee XJ. The rest of the
> lift went fine, just having trouble figuring out how to remove the
> mounting bolt on the axle flange for the sway bar end link since the RE
> unit comes with a different bolt that must be installed. It's a torx
> head bolt but doesn't unscrew even with a the largest breaker bar I can
> find. Tried hammering it out thinking it was press fit but had no luck
> with that either.
>
> Anyone have any experience with this that they can share? I tried
> searching the groups but wasn't able to find many threads on this
> topic.
>
> Thanks,
> John
>

 

John,

There are several things to try to help resolve the situation and you may
have already tried some of them.

Apply a penetrating oil such as PB Blaster several times a day for several
days to a week beforehand.

The assistance of a burley friend on the end of the breaker bar.

Addition of an extender to the breaker bar..... not recommended by the tool
manufacturer but a length of pipe over the handle can greatly increase the
effective length and torque multiplication.

Application of heat to the bolt. The expansion and following contraction
will sometimes break a bolt free.

Cutting-grinding-drilling removal of the old bolt.

Obviously you should start with methods that may inflict the least damage
i.e. don't start with a cutting torch

"John W." <jwagenleitner@gmail.com> wrote in message
news:1138730428.951890.311390@g14g2000cwa.googlegr oups.com...
> Having a problem installing the sway bar disconnects that came with my
> Rubiconexpress 3.5 inch lift on my '96 Cherokee XJ. The rest of the
> lift went fine, just having trouble figuring out how to remove the
> mounting bolt on the axle flange for the sway bar end link since the RE
> unit comes with a different bolt that must be installed. It's a torx
> head bolt but doesn't unscrew even with a the largest breaker bar I can
> find. Tried hammering it out thinking it was press fit but had no luck
> with that either.
>
> Anyone have any experience with this that they can share? I tried
> searching the groups but wasn't able to find many threads on this
> topic.
>
> Thanks,
> John
>

 

John,

There are several things to try to help resolve the situation and you may
have already tried some of them.

Apply a penetrating oil such as PB Blaster several times a day for several
days to a week beforehand.

The assistance of a burley friend on the end of the breaker bar.

Addition of an extender to the breaker bar..... not recommended by the tool
manufacturer but a length of pipe over the handle can greatly increase the
effective length and torque multiplication.

Application of heat to the bolt. The expansion and following contraction
will sometimes break a bolt free.

Cutting-grinding-drilling removal of the old bolt.

Obviously you should start with methods that may inflict the least damage
i.e. don't start with a cutting torch

"John W." <jwagenleitner@gmail.com> wrote in message
news:1138730428.951890.311390@g14g2000cwa.googlegr oups.com...
> Having a problem installing the sway bar disconnects that came with my
> Rubiconexpress 3.5 inch lift on my '96 Cherokee XJ. The rest of the
> lift went fine, just having trouble figuring out how to remove the
> mounting bolt on the axle flange for the sway bar end link since the RE
> unit comes with a different bolt that must be installed. It's a torx
> head bolt but doesn't unscrew even with a the largest breaker bar I can
> find. Tried hammering it out thinking it was press fit but had no luck
> with that either.
>
> Anyone have any experience with this that they can share? I tried
> searching the groups but wasn't able to find many threads on this
> topic.
>
> Thanks,
> John
>

 

I'll second billy. I'd try a soaking it in PB blaster for a few hours. TONS
of PB blaster. After a few hours, wipe the area clean, and using a propane
torch heat the head of the bolt and the surrounding area. I like to heat the
bolt heads untill they are almost red hot. Try the torx with the breaker bar
again and see what happens.

What year is your XJ? I had the RE 3.5" lift on a 91 XJ and it was awesome!
A 1" t-case drop and new U-joints cured my driveline vibes.

Carl


"John W." <jwagenleitner@gmail.com> wrote in message
news:1138730428.951890.311390@g14g2000cwa.googlegr oups.com...
> Having a problem installing the sway bar disconnects that came with my
> Rubiconexpress 3.5 inch lift on my '96 Cherokee XJ. The rest of the
> lift went fine, just having trouble figuring out how to remove the
> mounting bolt on the axle flange for the sway bar end link since the RE
> unit comes with a different bolt that must be installed. It's a torx
> head bolt but doesn't unscrew even with a the largest breaker bar I can
> find. Tried hammering it out thinking it was press fit but had no luck
> with that either.
>
> Anyone have any experience with this that they can share? I tried
> searching the groups but wasn't able to find many threads on this
> topic.
>
> Thanks,
> John
>

 

I'll second billy. I'd try a soaking it in PB blaster for a few hours. TONS
of PB blaster. After a few hours, wipe the area clean, and using a propane
torch heat the head of the bolt and the surrounding area. I like to heat the
bolt heads untill they are almost red hot. Try the torx with the breaker bar
again and see what happens.

What year is your XJ? I had the RE 3.5" lift on a 91 XJ and it was awesome!
A 1" t-case drop and new U-joints cured my driveline vibes.

Carl


"John W." <jwagenleitner@gmail.com> wrote in message
news:1138730428.951890.311390@g14g2000cwa.googlegr oups.com...
> Having a problem installing the sway bar disconnects that came with my
> Rubiconexpress 3.5 inch lift on my '96 Cherokee XJ. The rest of the
> lift went fine, just having trouble figuring out how to remove the
> mounting bolt on the axle flange for the sway bar end link since the RE
> unit comes with a different bolt that must be installed. It's a torx
> head bolt but doesn't unscrew even with a the largest breaker bar I can
> find. Tried hammering it out thinking it was press fit but had no luck
> with that either.
>
> Anyone have any experience with this that they can share? I tried
> searching the groups but wasn't able to find many threads on this
> topic.
>
> Thanks,
> John
>

 

I'll second billy. I'd try a soaking it in PB blaster for a few hours. TONS
of PB blaster. After a few hours, wipe the area clean, and using a propane
torch heat the head of the bolt and the surrounding area. I like to heat the
bolt heads untill they are almost red hot. Try the torx with the breaker bar
again and see what happens.

What year is your XJ? I had the RE 3.5" lift on a 91 XJ and it was awesome!
A 1" t-case drop and new U-joints cured my driveline vibes.

Carl


"John W." <jwagenleitner@gmail.com> wrote in message
news:1138730428.951890.311390@g14g2000cwa.googlegr oups.com...
> Having a problem installing the sway bar disconnects that came with my
> Rubiconexpress 3.5 inch lift on my '96 Cherokee XJ. The rest of the
> lift went fine, just having trouble figuring out how to remove the
> mounting bolt on the axle flange for the sway bar end link since the RE
> unit comes with a different bolt that must be installed. It's a torx
> head bolt but doesn't unscrew even with a the largest breaker bar I can
> find. Tried hammering it out thinking it was press fit but had no luck
> with that either.
>
> Anyone have any experience with this that they can share? I tried
> searching the groups but wasn't able to find many threads on this
> topic.
>
> Thanks,
> John
>

 

Thanks Billy Ray and Carl. What puzzles me is that I did soak the bolt
(and all other bolts every day for 3 days leading up to installation)
with a ton of pentrating oil. Looking closely at where the bolt goes
through the flange it almost appears to be welded (nearly not
noticeable). I'll give it few more tries with the pb blaster and
breaker bar. What I'd really like to confirm is whether or not this
bolt does really unscrew on a 1996 XJ.

Carl, my Cherokee is a 96 and I really like the lift so far. Except
for breaking one of the rear top shock bolts (still need to figure out
how to get fixed) and having a little trouble with the sway bars it was
a breeze to install. I got the kit with the full leaf's for the rear
and am thrilled to be able to see the tops of my 30x9.5 tires in the
rear wheel well now (old leafs were really tired). I actually haven't
had a chance to do much since I finished late on Sunday and have just
parked it waiting to get time from work to get it aligned. I put some
2 degree shims on the axle and haven't installed the 1 inch tcase drop
yet. I was going to see if I had vibes before doing that.

 

Thanks Billy Ray and Carl. What puzzles me is that I did soak the bolt
(and all other bolts every day for 3 days leading up to installation)
with a ton of pentrating oil. Looking closely at where the bolt goes
through the flange it almost appears to be welded (nearly not
noticeable). I'll give it few more tries with the pb blaster and
breaker bar. What I'd really like to confirm is whether or not this
bolt does really unscrew on a 1996 XJ.

Carl, my Cherokee is a 96 and I really like the lift so far. Except
for breaking one of the rear top shock bolts (still need to figure out
how to get fixed) and having a little trouble with the sway bars it was
a breeze to install. I got the kit with the full leaf's for the rear
and am thrilled to be able to see the tops of my 30x9.5 tires in the
rear wheel well now (old leafs were really tired). I actually haven't
had a chance to do much since I finished late on Sunday and have just
parked it waiting to get time from work to get it aligned. I put some
2 degree shims on the axle and haven't installed the 1 inch tcase drop
yet. I was going to see if I had vibes before doing that.

 

Thanks Billy Ray and Carl. What puzzles me is that I did soak the bolt
(and all other bolts every day for 3 days leading up to installation)
with a ton of pentrating oil. Looking closely at where the bolt goes
through the flange it almost appears to be welded (nearly not
noticeable). I'll give it few more tries with the pb blaster and
breaker bar. What I'd really like to confirm is whether or not this
bolt does really unscrew on a 1996 XJ.

Carl, my Cherokee is a 96 and I really like the lift so far. Except
for breaking one of the rear top shock bolts (still need to figure out
how to get fixed) and having a little trouble with the sway bars it was
a breeze to install. I got the kit with the full leaf's for the rear
and am thrilled to be able to see the tops of my 30x9.5 tires in the
rear wheel well now (old leafs were really tired). I actually haven't
had a chance to do much since I finished late on Sunday and have just
parked it waiting to get time from work to get it aligned. I put some
2 degree shims on the axle and haven't installed the 1 inch tcase drop
yet. I was going to see if I had vibes before doing that.