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View Full Version : Broken Rear Bump Stop Repair



dagr8tim
09-26-2011, 10:45 PM
I did this awhile back and thought I would share.

I snapped 2 of the bumpstop bolts when I was changing them. For the short term I punched the studs and the fastener into the subframe and threaded in some half inch bolts. I wasn't too happy with that solution because I felt they wouldn't be strong enough. While reading JeepForum, I came across a thread on fixing TJ transfer skid plates (http://www.jeepforum.com/forum/f9/nutsert-transfer-case-removal-install-390635/). I figured if it would work for a skid plate, it would work for a bumpstop. I wasn't about to spend $8 a pop on them from a dealership, and I knew I didn't need that much toughness. I found some nutserts at Fastenal (http://www.fastenal.com/web/products/detail.ex?sku=0125658&ucst=t) that would fit the holes in my subframe and should hold. I got 4 of them with tax and shipping for less than $9.

http://buckeyejeeps.com/albums/nutsert/Netsert_Tool_800x598.sized.jpg
Here's a nutsert on a homebrew installation tool. It's an M10 bolt with 2 flat washers, a 7/16 nut (anything large enough to spin freely on the bolt will work), and a star lock washer.

http://buckeyejeeps.com/albums/nutsert/Installation_Tools_800x598.sized.jpg
The only hand tools needed are a socket to turn the bolt, and a wrench to hold the nut from spinning.

http://buckeyejeeps.com/albums/nutsert/Nutsert_Installed_01_800x598.sized.jpg
Test Installation on one of the doors of my parts XJ. I wanted to see exactly how it installed before I got up under the Jeep where space was limited.

http://buckeyejeeps.com/albums/nutsert/Nutsert_Installed_02_800x598.sized.jpg
Cross section of the installation. The door panel wasn't vertical and was dented, so the bolt's not straight.

http://buckeyejeeps.com/albums/nutsert/Subframe_Nutsert_Installed_800x598.sized.jpg
Both nutserts installed in the frame.

http://buckeyejeeps.com/albums/nutsert/Bumpstop_Installed_800x598.sized.jpg
Bumpstop installed.

Here are some more random pics (http://buckeyejeeps.com/gallery/nutsert) of took while I was working on this project. If the fix seems to hold up, I may invest in a hand full of these when I replace my rear shocks next time. I will also be using these to install my factory TC skid plate. I would have used them on my front end skid plate if I would have known about them back then.

bluedragon436
09-27-2011, 12:14 AM
Thanks for this write-up.. as I know I need to install some bumpstops as my stock ones are shot, and way too short for my lift height anyways.. so I'm sure I'll need to make use of this write-up when I do that..

Mudderoy
09-27-2011, 09:05 AM
I've never seen these before, well not out anyway. I bet this is what I need to attach my transfer case skid back to the transmission cross member.

dagr8tim
09-27-2011, 09:09 AM
I've never seen these before, well not out anyway. I bet this is what I need to attach my transfer case skid back to the transmission cross member.

Bingo. I'm going to use these to mount the transfer case skid on my 98 SE that didn't come with any skids.

These come in a great many sizes and should be good for anywhere that you need to put a bolt into sheet metal. The price is also pretty good, and fairly easy to install.

senatE
10-01-2011, 01:10 AM
thanks for this!! i guess i know how to fix my friends now lol.

Showtime3492
10-01-2011, 11:22 AM
I gotta put my 2 cents in on this cuz those bump stops are the devil... I had to cut out 15 inches of frame on the passenger side and 8 on the driver cuz of those things they hold water and will without a doubt be the root of cancer back there. If you do this and you are cancer free on those spots of the frame install a new bumpstop and put some rtv around it to stop it from trapping so much water.... Me I just cut them out and eliminated them. Because they are needed but not nearly as much as a coils bumpstop and its hard for me to stuff the rear that far to get to where I need them. Looks good though like the tech.

cherokeewrecker
10-01-2011, 05:28 PM
I did this awhile back and thought I would share.

I snapped 2 of the bumpstop bolts when I was changing them. For the short term I punched the studs and the fastener into the subframe and threaded in some half inch bolts. I wasn't too happy with that solution because I felt they wouldn't be strong enough. While reading JeepForum, I came across a thread on fixing TJ transfer skid plates (http://www.jeepforum.com/forum/f9/nutsert-transfer-case-removal-install-390635/). I figured if it would work for a skid plate, it would work for a bumpstop. I wasn't about to spend $8 a pop on them from a dealership, and I knew I didn't need that much toughness. I found some nutserts at Fastenal (http://www.fastenal.com/web/products/detail.ex?sku=0125658&ucst=t) that would fit the holes in my subframe and should hold. I got 4 of them with tax and shipping for less than $9.

http://buckeyejeeps.com/albums/nutsert/Netsert_Tool_800x598.sized.jpg
Here's a nutsert on a homebrew installation tool. It's an M10 bolt with 2 flat washers, a 7/16 nut (anything large enough to spin freely on the bolt will work), and a star lock washer.

http://buckeyejeeps.com/albums/nutsert/Installation_Tools_800x598.sized.jpg
The only hand tools needed are a socket to turn the bolt, and a wrench to hold the nut from spinning.

http://buckeyejeeps.com/albums/nutsert/Nutsert_Installed_01_800x598.sized.jpg
Test Installation on one of the doors of my parts XJ. I wanted to see exactly how it installed before I got up under the Jeep where space was limited.

http://buckeyejeeps.com/albums/nutsert/Nutsert_Installed_02_800x598.sized.jpg
Cross section of the installation. The door panel wasn't vertical and was dented, so the bolt's not straight.

http://buckeyejeeps.com/albums/nutsert/Subframe_Nutsert_Installed_800x598.sized.jpg
Both nutserts installed in the frame.

http://buckeyejeeps.com/albums/nutsert/Bumpstop_Installed_800x598.sized.jpg
Bumpstop installed.

Here are some more random pics (http://buckeyejeeps.com/gallery/nutsert) of took while I was working on this project. If the fix seems to hold up, I may invest in a hand full of these when I replace my rear shocks next time. I will also be using these to install my factory TC skid plate. I would have used them on my front end skid plate if I would have known about them back then.



Those are a pretty dang good idea, think I may stock up on some of those while I work on the jeep this winter

Converted96XJ
10-01-2011, 08:48 PM
I like this idea, and if i need to extend my bump stops I will probably go this route. I already bought the longer bump stops, one side the bolts came out, the other they both broke. However I just put in some larger self tappers and they are holding it in pretty well. I dont think there will be too much issue with the self tappers seeing that its upward force on the bump stop.

dagr8tim
10-01-2011, 08:50 PM
I like this idea, and if i need to extend my bump stops I will probably go this route. I already bought the longer bump stops, one side the bolts came out, the other they both broke. However I just put in some larger self tappers and they are holding it in pretty well. I dont think there will be too much issue with the self tappers seeing that its upward force on the bump stop.

I understand. The only thing about the nutcert router, is that I know the bolt is an M10, and I can find them anywhere if I decide to drill a chunk of square tubing to extend my bumpstops.

Converted96XJ
10-01-2011, 08:55 PM
thats what im saying, that size is easy to find. I plan to extend if needed and when/if I do, this is the route I would go. However my rear floor is so rotted I could just weld new nuts in the frame rail... lol nice work!

dagr8tim
10-01-2011, 09:00 PM
thats what im saying, that size is easy to find. I plan to extend if needed and when/if I do, this is the route I would go. However my rear floor is so rotted I could just weld new nuts in the frame rail... lol nice work!

I got lucky that my Jeep was a southern Jeep (Ky) and the floor was mint when I yanked the carpet to change it. I can't justify cutting the floor.

jeepxj95
10-02-2011, 11:55 PM
I got lucky that my Jeep was a southern Jeep (Ky) and the floor was mint when I yanked the carpet to change it. I can't justify cutting the floor.

bedline the floors and rockers now to keep them mint

dagr8tim
10-02-2011, 11:56 PM
bedline the floors and rockers now to keep them mint

Rockers are already getting crispy. The rot from the inside.

senatE
10-03-2011, 12:55 AM
wow my post got deleted? :\

Mudderoy
10-03-2011, 01:00 AM
wow my post got deleted? :\

Which one. I deleted a duplicate post, but it wasn't yours.

Botakbeng
08-18-2012, 01:03 PM
Hey, thanks for sharing....great idea.
Wondering how did you remove those broken bolts.

Thanks in advance!

dagr8tim
08-18-2012, 01:07 PM
Punch and a 3 pound mini sledge. I knocked the broken bolt and the weld nut into the subframe.

Botakbeng
08-19-2012, 08:34 AM
Cool!
Appreciate it!