How to fix ovaled out track bar mounts

[4.3LXJ]

It happens to a lot of us sooner or later. The holes on the axle track bar mount become oval instead of round. Then you keep getting death wobble.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0583_zpsa3abda38.jpg

The only way to fix it is to add some steel. Here is a way to do that and make it so much beefier.

First take a dremel or die grinder with a cut off wheel and cut off the outside flange.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0584_zps143de7c8.jpg

Then enlarge the original bolt hole. I used a 7/8" drill bit for this

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0589_zpscb844a50.jpg

Now you need to make a new piece for this space. I used some scrap 2X4X3/16" rectangular tubing, or you can use a small 3" piece of 2X2X3/16" square tubing. Cut off the excess 1 5/8" from the edge and mark it 1 1/4" from the factory edge and 1 1/2" from the end.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0585_zps69045b03.jpg

Drilling a pilot hole is real handy for this. It is necessary to make this as straight as possible and the final hole has to be 3/8" so the bolt will fit tight in the metal and bushing.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0586_zpse6a21760.jpg

The backside outer edge where the sway bar mount needs to be notched.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0587_zpsd7d1c360.jpg

Next tack weld a nut on the back side. I used a self locking nut here. We don't want it to work loose again. Line it up with a bolt through both holes. This is a tack weld, not structural. It needs to fit in that large hole you drilled in the old bracket.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0594_zps11c8747c.jpg

Next check the fit and weld it into place.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0596_zpsb47842bd.jpg

Next, install the track bar. If you measured correctly, your steering wheel will be exactly as it was before. If not, it is easily adjusted to be centered again

[jeepin_idaho]

This is an extremely timely post. I just noticed that my track bar mount on the axle is badly cracked and is close to being completely free from the axle. Anyone know of a company that has a prefabbed mount? If not, I'll be building my own...which is probably the fastest solution. I'll post a picture of this mess next time I walk out to the XJ.

[xj4life2]

For a quick fix I normally weld a washer on to the mount and all is well

[jeepin_idaho]

http://img.tapatalk.com/d/13/10/26/eny4usat.jpg

Is this bad? :mad:

Dan
http://facebook.com/the4x4podcast

[4.3LXJ]

Might need a little welding to fix

[07Negative]

My passenger side upper control arm bracket has done this (axle side). I just welded the bushing for a quick fix. Which means, it allows me to neglect the real fix. Is it just me, or do the Dremel cut off wheels suck? I had a packet of them. Something like 20 cut off wheels. They break really easy. I love the fact that you can get into tight places with them though.

[XJ Wheeler]

My passenger side upper control arm bracket has done this (axle side). I just welded the bushing for a quick fix. Which means, it allows me to neglect the real fix. Is it just me, or do the Dremel cut off wheels suck? I had a packet of them. Something like 20 cut off wheels. They break really easy. I love the fact that you can get into tight places with them though.

Try the reinforced wheels. They're expensive at only 5 for about $7, but I've never had one break.

Dremel 426 Fiberglass Reinforced Cut-Off Wheels 1- 1/4" Dia., .045" Thick, 5 Pack:Amazon:Home Improvement@@AMEPARAM@@http://ecx.images-amazon.com/images/I/41Z0aZFjSNL.@@AMEPARAM@@41Z0aZFjSNL

Sent via messenger pigeon - i talk, he types.

[OldFaurt]

It happens to a lot of us sooner or later. The holes on the axle track bar mount become oval instead of round. Then you keep getting death wobble.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0583_zpsa3abda38.jpg

The only way to fix it is to add some steel. Here is a way to do that and make it so much beefier.

First take a dremel or die grinder with a cut off wheel and cut off the outside flange.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0584_zps143de7c8.jpg

Then enlarge the original bolt hole. I used a 7/8" drill bit for this

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0589_zpscb844a50.jpg

Now you need to make a new piece for this space. I used some scrap 2X4X3/16" rectangular tubing, or you can use a small 3" piece of 2X2X3/16" square tubing. Cut off the excess 1 5/8" from the edge and mark it 1 1/4" from the factory edge and 1 1/2" from the end.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0585_zps69045b03.jpg

Drilling a pilot hole is real handy for this. It is necessary to make this as straight as possible and the final hole has to be 3/8" so the bolt will fit tight in the metal and bushing.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0586_zpse6a21760.jpg

The backside outer edge where the sway bar mount needs to be notched.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0587_zpsd7d1c360.jpg

Next tack weld a nut on the back side. I used a self locking nut here. We don't want it to work loose again. Line it up with a bolt through both holes. This is a tack weld, not structural. It needs to fit in that large hole you drilled in the old bracket.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0594_zps11c8747c.jpg

Next check the fit and weld it into place.

http://i649.photobucket.com/albums/uu215/warriorsuspension/Pauls%20TJ/IMG_0596_zpsb47842bd.jpg

Next, install the track bar. If you measured correctly, your steering wheel will be exactly as it was before. If not, it is easily adjusted to be centered again

Wow, Very nice job! I better check mine and be sure it is good or looks like yours!