|
Lift install NIGHTMARE
This is long, but it details the problems my friend Shaun and I had
installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my 91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, a welder, and plenty of drills, grinders, and other power tools. We started on Friday at 3pm. We didn't leave the shop untill Saturday at 3am. Let me tell you, I have a new respect for stuck bolts. All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 with a torch and muscle them out. The last, the passenger side front leaf spring bolt.. sheared off in the bushing AND broke the weld-nut inside the frame. Yes, I broke them both. We had to bend the spring hangar and cut the spring eye in half. THEN we had to cut the bolt - it turned out the bushing's sleeve had siezed to the bolt. Now we had a hole in the frame with a broken weld-nut and a piece of bolt sticking out. Not good. Plasma cutter wasn't working. We decided to cut a hole in the frame extension welded on where the weld-nut resided, pull it out, and weld a new piece in place with a new weld nut. Without the plasma cutter, we resorted to an air-driven die grinder. Two hours later, the patch was welded into place. The remainder of the rear was pretty uneventful, but I had to loose the crappy tow hitch. What is it with this passenger side? Lower control arm, upper bolt. Same thing. Seized sleeve in the bushing. Ridiculous. We ground it down to flush with the bracket, put a pickle fork between the braket and used a BFH to make a gap and rip the control arm out. Then, for some reason, on the install of the new control arms, the bolt I had just taken out of the driver's side lower control arm frame end mount wouldn't go back thru the frame. None of them would. Scrounge up another bolt.. So we installed a longer rear brake line, and I tried to re-position the driver's side front brake line mount after I straightened the tubes as outlined by RE. No dice. Either way, we need to bleed the brakes. This is about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 miles with my E-brake. This RE 3.5" lift was a FIGHT every step of the way, an absolute nightmare. I don't think that it had anything to do with Rubicon's parts, design, or quality. The kit with the DT3 shocks rides well and smooth. Most of the parts were correct and fit well. I did have to bore out one side of one lower control arm axle end bolt hole. I also re-drilled the track bar mount. To make matters worse, my spare car that i was going to give to someone whom had their house burn down.... it was stolen last night! All I can say is..wow.. Carl |
Re: Lift install NIGHTMARE
2 words: PB Blaster.
"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my > 91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of > air, a welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut > the spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame > with a broken weld-nut and a piece of bolt sticking out. Not good. Plasma > cutter wasn't working. We decided to cut a hole in the frame extension > welded on where the weld-nut resided, pull it out, and weld a new piece in > place with a new weld nut. Without the plasma cutter, we resorted to an > air-driven die grinder. Two hours later, the patch was welded into place. > The remainder of the rear was pretty uneventful, but I had to loose the > crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to > flush with the bracket, put a pickle fork between the braket and used a > BFH to make a gap and rip the control arm out. Then, for some reason, on > the install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute > nightmare. I don't think that it had anything to do with Rubicon's parts, > design, or quality. The kit with the DT3 shocks rides well and smooth. > Most of the parts were correct and fit well. I did have to bore out one > side of one lower control arm axle end bolt hole. I also re-drilled the > track bar mount. > > To make matters worse, my spare car that i was going to give to someone > whom had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl > |
Re: Lift install NIGHTMARE
2 words: PB Blaster.
"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my > 91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of > air, a welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut > the spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame > with a broken weld-nut and a piece of bolt sticking out. Not good. Plasma > cutter wasn't working. We decided to cut a hole in the frame extension > welded on where the weld-nut resided, pull it out, and weld a new piece in > place with a new weld nut. Without the plasma cutter, we resorted to an > air-driven die grinder. Two hours later, the patch was welded into place. > The remainder of the rear was pretty uneventful, but I had to loose the > crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to > flush with the bracket, put a pickle fork between the braket and used a > BFH to make a gap and rip the control arm out. Then, for some reason, on > the install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute > nightmare. I don't think that it had anything to do with Rubicon's parts, > design, or quality. The kit with the DT3 shocks rides well and smooth. > Most of the parts were correct and fit well. I did have to bore out one > side of one lower control arm axle end bolt hole. I also re-drilled the > track bar mount. > > To make matters worse, my spare car that i was going to give to someone > whom had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl > |
Re: Lift install NIGHTMARE
2 words: PB Blaster.
"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my > 91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of > air, a welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut > the spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame > with a broken weld-nut and a piece of bolt sticking out. Not good. Plasma > cutter wasn't working. We decided to cut a hole in the frame extension > welded on where the weld-nut resided, pull it out, and weld a new piece in > place with a new weld nut. Without the plasma cutter, we resorted to an > air-driven die grinder. Two hours later, the patch was welded into place. > The remainder of the rear was pretty uneventful, but I had to loose the > crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to > flush with the bracket, put a pickle fork between the braket and used a > BFH to make a gap and rip the control arm out. Then, for some reason, on > the install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute > nightmare. I don't think that it had anything to do with Rubicon's parts, > design, or quality. The kit with the DT3 shocks rides well and smooth. > Most of the parts were correct and fit well. I did have to bore out one > side of one lower control arm axle end bolt hole. I also re-drilled the > track bar mount. > > To make matters worse, my spare car that i was going to give to someone > whom had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl > |
Re: Lift install NIGHTMARE
2 words: three cans.
Carl "Matt Macchiarolo" <matt@nospamplease.com> wrote in message news:3d2dndj4RPx8wuLeRVn-qA@comcast.com... >2 words: PB Blaster. > > "Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message > news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >> 91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of >> air, a welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 with a torch and muscle them out. The last, the passenger side front >> leaf spring bolt.. sheared off in the bushing AND broke the weld-nut >> inside the frame. Yes, I broke them both. We had to bend the spring >> hangar and cut the spring eye in half. THEN we had to cut the bolt - it >> turned out the bushing's sleeve had siezed to the bolt. Now we had a hole >> in the frame with a broken weld-nut and a piece of bolt sticking out. Not >> good. Plasma cutter wasn't working. We decided to cut a hole in the frame >> extension welded on where the weld-nut resided, pull it out, and weld a >> new piece in place with a new weld nut. Without the plasma cutter, we >> resorted to an air-driven die grinder. Two hours later, the patch was >> welded into place. The remainder of the rear was pretty uneventful, but I >> had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >> flush with the bracket, put a pickle fork between the braket and used a >> BFH to make a gap and rip the control arm out. Then, for some reason, on >> the install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute >> nightmare. I don't think that it had anything to do with Rubicon's parts, >> design, or quality. The kit with the DT3 shocks rides well and smooth. >> Most of the parts were correct and fit well. I did have to bore out one >> side of one lower control arm axle end bolt hole. I also re-drilled the >> track bar mount. >> >> To make matters worse, my spare car that i was going to give to someone >> whom had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl >> > > |
Re: Lift install NIGHTMARE
2 words: three cans.
Carl "Matt Macchiarolo" <matt@nospamplease.com> wrote in message news:3d2dndj4RPx8wuLeRVn-qA@comcast.com... >2 words: PB Blaster. > > "Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message > news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >> 91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of >> air, a welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 with a torch and muscle them out. The last, the passenger side front >> leaf spring bolt.. sheared off in the bushing AND broke the weld-nut >> inside the frame. Yes, I broke them both. We had to bend the spring >> hangar and cut the spring eye in half. THEN we had to cut the bolt - it >> turned out the bushing's sleeve had siezed to the bolt. Now we had a hole >> in the frame with a broken weld-nut and a piece of bolt sticking out. Not >> good. Plasma cutter wasn't working. We decided to cut a hole in the frame >> extension welded on where the weld-nut resided, pull it out, and weld a >> new piece in place with a new weld nut. Without the plasma cutter, we >> resorted to an air-driven die grinder. Two hours later, the patch was >> welded into place. The remainder of the rear was pretty uneventful, but I >> had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >> flush with the bracket, put a pickle fork between the braket and used a >> BFH to make a gap and rip the control arm out. Then, for some reason, on >> the install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute >> nightmare. I don't think that it had anything to do with Rubicon's parts, >> design, or quality. The kit with the DT3 shocks rides well and smooth. >> Most of the parts were correct and fit well. I did have to bore out one >> side of one lower control arm axle end bolt hole. I also re-drilled the >> track bar mount. >> >> To make matters worse, my spare car that i was going to give to someone >> whom had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl >> > > |
Re: Lift install NIGHTMARE
2 words: three cans.
Carl "Matt Macchiarolo" <matt@nospamplease.com> wrote in message news:3d2dndj4RPx8wuLeRVn-qA@comcast.com... >2 words: PB Blaster. > > "Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message > news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >> 91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of >> air, a welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 with a torch and muscle them out. The last, the passenger side front >> leaf spring bolt.. sheared off in the bushing AND broke the weld-nut >> inside the frame. Yes, I broke them both. We had to bend the spring >> hangar and cut the spring eye in half. THEN we had to cut the bolt - it >> turned out the bushing's sleeve had siezed to the bolt. Now we had a hole >> in the frame with a broken weld-nut and a piece of bolt sticking out. Not >> good. Plasma cutter wasn't working. We decided to cut a hole in the frame >> extension welded on where the weld-nut resided, pull it out, and weld a >> new piece in place with a new weld nut. Without the plasma cutter, we >> resorted to an air-driven die grinder. Two hours later, the patch was >> welded into place. The remainder of the rear was pretty uneventful, but I >> had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >> flush with the bracket, put a pickle fork between the braket and used a >> BFH to make a gap and rip the control arm out. Then, for some reason, on >> the install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute >> nightmare. I don't think that it had anything to do with Rubicon's parts, >> design, or quality. The kit with the DT3 shocks rides well and smooth. >> Most of the parts were correct and fit well. I did have to bore out one >> side of one lower control arm axle end bolt hole. I also re-drilled the >> track bar mount. >> >> To make matters worse, my spare car that i was going to give to someone >> whom had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl >> > > |
Re: Lift install NIGHTMARE
Ya gotta let the PB blaster work for several days for the really
stubborn stuff. Stubborn cases take a daily dose of heat then more PB for a week. :( But once you snap the bolt, nothing to do but drill it out. Carl wrote: > 2 words: three cans. > > Carl > > "Matt Macchiarolo" <matt@nospamplease.com> wrote in message > news:3d2dndj4RPx8wuLeRVn-qA@comcast.com... > >>2 words: PB Blaster. >> >>"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message >>news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> >>>This is long, but it details the problems my friend Shaun and I had >>>installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >>>91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of >>>air, a welder, and plenty of drills, grinders, and other power tools. >>> >>>We started on Friday at 3pm. We didn't leave the shop untill Saturday at >>>3am. Let me tell you, I have a new respect for stuck bolts. >>> >>>All four rear leaf spring bolts were siezed. I was able to heat 3 of the >>>4 with a torch and muscle them out. The last, the passenger side front >>>leaf spring bolt.. sheared off in the bushing AND broke the weld-nut >>>inside the frame. Yes, I broke them both. We had to bend the spring >>>hangar and cut the spring eye in half. THEN we had to cut the bolt - it >>>turned out the bushing's sleeve had siezed to the bolt. Now we had a hole >>>in the frame with a broken weld-nut and a piece of bolt sticking out. Not >>>good. Plasma cutter wasn't working. We decided to cut a hole in the frame >>>extension welded on where the weld-nut resided, pull it out, and weld a >>>new piece in place with a new weld nut. Without the plasma cutter, we >>>resorted to an air-driven die grinder. Two hours later, the patch was >>>welded into place. The remainder of the rear was pretty uneventful, but I >>>had to loose the crappy tow hitch. >>> >>>What is it with this passenger side? Lower control arm, upper bolt. Same >>>thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >>>flush with the bracket, put a pickle fork between the braket and used a >>>BFH to make a gap and rip the control arm out. Then, for some reason, on >>>the install of the new control arms, the bolt I had just taken out of the >>>driver's side lower control arm frame end mount wouldn't go back thru the >>>frame. None of them would. Scrounge up another bolt.. >>> >>>So we installed a longer rear brake line, and I tried to re-position the >>>driver's side front brake line mount after I straightened the tubes as >>>outlined by RE. No dice. Either way, we need to bleed the brakes. This is >>>about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >>>Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >>>miles with my E-brake. >>> >>>This RE 3.5" lift was a FIGHT every step of the way, an absolute >>>nightmare. I don't think that it had anything to do with Rubicon's parts, >>>design, or quality. The kit with the DT3 shocks rides well and smooth. >>>Most of the parts were correct and fit well. I did have to bore out one >>>side of one lower control arm axle end bolt hole. I also re-drilled the >>>track bar mount. >>> >>>To make matters worse, my spare car that i was going to give to someone >>>whom had their house burn down.... it was stolen last night! >>> >>>All I can say is..wow.. >>> >>>Carl >>> >> >> > > |
Re: Lift install NIGHTMARE
Ya gotta let the PB blaster work for several days for the really
stubborn stuff. Stubborn cases take a daily dose of heat then more PB for a week. :( But once you snap the bolt, nothing to do but drill it out. Carl wrote: > 2 words: three cans. > > Carl > > "Matt Macchiarolo" <matt@nospamplease.com> wrote in message > news:3d2dndj4RPx8wuLeRVn-qA@comcast.com... > >>2 words: PB Blaster. >> >>"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message >>news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> >>>This is long, but it details the problems my friend Shaun and I had >>>installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >>>91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of >>>air, a welder, and plenty of drills, grinders, and other power tools. >>> >>>We started on Friday at 3pm. We didn't leave the shop untill Saturday at >>>3am. Let me tell you, I have a new respect for stuck bolts. >>> >>>All four rear leaf spring bolts were siezed. I was able to heat 3 of the >>>4 with a torch and muscle them out. The last, the passenger side front >>>leaf spring bolt.. sheared off in the bushing AND broke the weld-nut >>>inside the frame. Yes, I broke them both. We had to bend the spring >>>hangar and cut the spring eye in half. THEN we had to cut the bolt - it >>>turned out the bushing's sleeve had siezed to the bolt. Now we had a hole >>>in the frame with a broken weld-nut and a piece of bolt sticking out. Not >>>good. Plasma cutter wasn't working. We decided to cut a hole in the frame >>>extension welded on where the weld-nut resided, pull it out, and weld a >>>new piece in place with a new weld nut. Without the plasma cutter, we >>>resorted to an air-driven die grinder. Two hours later, the patch was >>>welded into place. The remainder of the rear was pretty uneventful, but I >>>had to loose the crappy tow hitch. >>> >>>What is it with this passenger side? Lower control arm, upper bolt. Same >>>thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >>>flush with the bracket, put a pickle fork between the braket and used a >>>BFH to make a gap and rip the control arm out. Then, for some reason, on >>>the install of the new control arms, the bolt I had just taken out of the >>>driver's side lower control arm frame end mount wouldn't go back thru the >>>frame. None of them would. Scrounge up another bolt.. >>> >>>So we installed a longer rear brake line, and I tried to re-position the >>>driver's side front brake line mount after I straightened the tubes as >>>outlined by RE. No dice. Either way, we need to bleed the brakes. This is >>>about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >>>Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >>>miles with my E-brake. >>> >>>This RE 3.5" lift was a FIGHT every step of the way, an absolute >>>nightmare. I don't think that it had anything to do with Rubicon's parts, >>>design, or quality. The kit with the DT3 shocks rides well and smooth. >>>Most of the parts were correct and fit well. I did have to bore out one >>>side of one lower control arm axle end bolt hole. I also re-drilled the >>>track bar mount. >>> >>>To make matters worse, my spare car that i was going to give to someone >>>whom had their house burn down.... it was stolen last night! >>> >>>All I can say is..wow.. >>> >>>Carl >>> >> >> > > |
Re: Lift install NIGHTMARE
Ya gotta let the PB blaster work for several days for the really
stubborn stuff. Stubborn cases take a daily dose of heat then more PB for a week. :( But once you snap the bolt, nothing to do but drill it out. Carl wrote: > 2 words: three cans. > > Carl > > "Matt Macchiarolo" <matt@nospamplease.com> wrote in message > news:3d2dndj4RPx8wuLeRVn-qA@comcast.com... > >>2 words: PB Blaster. >> >>"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message >>news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> >>>This is long, but it details the problems my friend Shaun and I had >>>installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >>>91 XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of >>>air, a welder, and plenty of drills, grinders, and other power tools. >>> >>>We started on Friday at 3pm. We didn't leave the shop untill Saturday at >>>3am. Let me tell you, I have a new respect for stuck bolts. >>> >>>All four rear leaf spring bolts were siezed. I was able to heat 3 of the >>>4 with a torch and muscle them out. The last, the passenger side front >>>leaf spring bolt.. sheared off in the bushing AND broke the weld-nut >>>inside the frame. Yes, I broke them both. We had to bend the spring >>>hangar and cut the spring eye in half. THEN we had to cut the bolt - it >>>turned out the bushing's sleeve had siezed to the bolt. Now we had a hole >>>in the frame with a broken weld-nut and a piece of bolt sticking out. Not >>>good. Plasma cutter wasn't working. We decided to cut a hole in the frame >>>extension welded on where the weld-nut resided, pull it out, and weld a >>>new piece in place with a new weld nut. Without the plasma cutter, we >>>resorted to an air-driven die grinder. Two hours later, the patch was >>>welded into place. The remainder of the rear was pretty uneventful, but I >>>had to loose the crappy tow hitch. >>> >>>What is it with this passenger side? Lower control arm, upper bolt. Same >>>thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >>>flush with the bracket, put a pickle fork between the braket and used a >>>BFH to make a gap and rip the control arm out. Then, for some reason, on >>>the install of the new control arms, the bolt I had just taken out of the >>>driver's side lower control arm frame end mount wouldn't go back thru the >>>frame. None of them would. Scrounge up another bolt.. >>> >>>So we installed a longer rear brake line, and I tried to re-position the >>>driver's side front brake line mount after I straightened the tubes as >>>outlined by RE. No dice. Either way, we need to bleed the brakes. This is >>>about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >>>Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >>>miles with my E-brake. >>> >>>This RE 3.5" lift was a FIGHT every step of the way, an absolute >>>nightmare. I don't think that it had anything to do with Rubicon's parts, >>>design, or quality. The kit with the DT3 shocks rides well and smooth. >>>Most of the parts were correct and fit well. I did have to bore out one >>>side of one lower control arm axle end bolt hole. I also re-drilled the >>>track bar mount. >>> >>>To make matters worse, my spare car that i was going to give to someone >>>whom had their house burn down.... it was stolen last night! >>> >>>All I can say is..wow.. >>> >>>Carl >>> >> >> > > |
Re: Lift install NIGHTMARE
I feel for you! When I took my CJ7 apart only one bolt came out of the
tub, the rest spun or snapped. I took my spring lift job to a spring shop! They torched the suckers apart. Mike 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00 88 Cherokee 235 BFG AT's Canadian Off Road Trips Photos: Non members can still view! Aug./05 http://www.imagestation.com/album/in...?id=2120343242 (More Off Road album links at bottom of the view page) Carl wrote: > > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my 91 > XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, a > welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut the > spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame with > a broken weld-nut and a piece of bolt sticking out. Not good. Plasma cutter > wasn't working. We decided to cut a hole in the frame extension welded on > where the weld-nut resided, pull it out, and weld a new piece in place with > a new weld nut. Without the plasma cutter, we resorted to an air-driven die > grinder. Two hours later, the patch was welded into place. The remainder of > the rear was pretty uneventful, but I had to loose the crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to flush > with the bracket, put a pickle fork between the braket and used a BFH to > make a gap and rip the control arm out. Then, for some reason, on the > install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute nightmare. > I don't think that it had anything to do with Rubicon's parts, design, or > quality. The kit with the DT3 shocks rides well and smooth. Most of the > parts were correct and fit well. I did have to bore out one side of one > lower control arm axle end bolt hole. I also re-drilled the track bar mount. > > To make matters worse, my spare car that i was going to give to someone whom > had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl |
Re: Lift install NIGHTMARE
I feel for you! When I took my CJ7 apart only one bolt came out of the
tub, the rest spun or snapped. I took my spring lift job to a spring shop! They torched the suckers apart. Mike 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00 88 Cherokee 235 BFG AT's Canadian Off Road Trips Photos: Non members can still view! Aug./05 http://www.imagestation.com/album/in...?id=2120343242 (More Off Road album links at bottom of the view page) Carl wrote: > > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my 91 > XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, a > welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut the > spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame with > a broken weld-nut and a piece of bolt sticking out. Not good. Plasma cutter > wasn't working. We decided to cut a hole in the frame extension welded on > where the weld-nut resided, pull it out, and weld a new piece in place with > a new weld nut. Without the plasma cutter, we resorted to an air-driven die > grinder. Two hours later, the patch was welded into place. The remainder of > the rear was pretty uneventful, but I had to loose the crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to flush > with the bracket, put a pickle fork between the braket and used a BFH to > make a gap and rip the control arm out. Then, for some reason, on the > install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute nightmare. > I don't think that it had anything to do with Rubicon's parts, design, or > quality. The kit with the DT3 shocks rides well and smooth. Most of the > parts were correct and fit well. I did have to bore out one side of one > lower control arm axle end bolt hole. I also re-drilled the track bar mount. > > To make matters worse, my spare car that i was going to give to someone whom > had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl |
Re: Lift install NIGHTMARE
I feel for you! When I took my CJ7 apart only one bolt came out of the
tub, the rest spun or snapped. I took my spring lift job to a spring shop! They torched the suckers apart. Mike 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00 88 Cherokee 235 BFG AT's Canadian Off Road Trips Photos: Non members can still view! Aug./05 http://www.imagestation.com/album/in...?id=2120343242 (More Off Road album links at bottom of the view page) Carl wrote: > > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my 91 > XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, a > welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut the > spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame with > a broken weld-nut and a piece of bolt sticking out. Not good. Plasma cutter > wasn't working. We decided to cut a hole in the frame extension welded on > where the weld-nut resided, pull it out, and weld a new piece in place with > a new weld nut. Without the plasma cutter, we resorted to an air-driven die > grinder. Two hours later, the patch was welded into place. The remainder of > the rear was pretty uneventful, but I had to loose the crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to flush > with the bracket, put a pickle fork between the braket and used a BFH to > make a gap and rip the control arm out. Then, for some reason, on the > install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute nightmare. > I don't think that it had anything to do with Rubicon's parts, design, or > quality. The kit with the DT3 shocks rides well and smooth. Most of the > parts were correct and fit well. I did have to bore out one side of one > lower control arm axle end bolt hole. I also re-drilled the track bar mount. > > To make matters worse, my spare car that i was going to give to someone whom > had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl |
Re: Lift install NIGHTMARE
Hi Carl,
plus an impact wrench. Always tighten each side to remove enough of the peined threads to able to spin them off without galling. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > 2 words: three cans. > > Carl |
Re: Lift install NIGHTMARE
Hi Carl,
plus an impact wrench. Always tighten each side to remove enough of the peined threads to able to spin them off without galling. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > 2 words: three cans. > > Carl |
Re: Lift install NIGHTMARE
Hi Carl,
plus an impact wrench. Always tighten each side to remove enough of the peined threads to able to spin them off without galling. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > 2 words: three cans. > > Carl |
Re: Lift install NIGHTMARE
Bill -
We had a big ass 3/4" drive impact wrench that could spin my arms off. Hopefully it comes apart easier next time. Carl "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message news:437F7AEB.2349F7FB@cox.net... > Hi Carl, > plus an impact wrench. Always tighten each side to remove enough of > the peined threads to able to spin them off without galling. > God Bless America, Bill O|||||||O > mailto:-------------------- http://www.----------.com/ > > Carl wrote: >> >> 2 words: three cans. >> >> Carl |
Re: Lift install NIGHTMARE
Bill -
We had a big ass 3/4" drive impact wrench that could spin my arms off. Hopefully it comes apart easier next time. Carl "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message news:437F7AEB.2349F7FB@cox.net... > Hi Carl, > plus an impact wrench. Always tighten each side to remove enough of > the peined threads to able to spin them off without galling. > God Bless America, Bill O|||||||O > mailto:-------------------- http://www.----------.com/ > > Carl wrote: >> >> 2 words: three cans. >> >> Carl |
Re: Lift install NIGHTMARE
Bill -
We had a big ass 3/4" drive impact wrench that could spin my arms off. Hopefully it comes apart easier next time. Carl "L.W. ("ßill") ------ III" <----------@cox.net> wrote in message news:437F7AEB.2349F7FB@cox.net... > Hi Carl, > plus an impact wrench. Always tighten each side to remove enough of > the peined threads to able to spin them off without galling. > God Bless America, Bill O|||||||O > mailto:-------------------- http://www.----------.com/ > > Carl wrote: >> >> 2 words: three cans. >> >> Carl |
Re: Lift install NIGHTMARE
Cool. I was able to torch most of them, but suffered a bad burn on one of my
fingers from molten bushing. Carl "Mike Romain" <romainm@sympatico.ca> wrote in message news:437F6C20.433A2877@sympatico.ca... >I feel for you! When I took my CJ7 apart only one bolt came out of the > tub, the rest spun or snapped. I took my spring lift job to a spring > shop! They torched the suckers apart. > > Mike > 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00 > 88 Cherokee 235 BFG AT's > Canadian Off Road Trips Photos: Non members can still view! > Aug./05 http://www.imagestation.com/album/in...?id=2120343242 > (More Off Road album links at bottom of the view page) > > Carl wrote: >> >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >> 91 >> XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, >> a >> welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 >> with a torch and muscle them out. The last, the passenger side front leaf >> spring bolt.. sheared off in the bushing AND broke the weld-nut inside >> the >> frame. Yes, I broke them both. We had to bend the spring hangar and cut >> the >> spring eye in half. THEN we had to cut the bolt - it turned out the >> bushing's sleeve had siezed to the bolt. Now we had a hole in the frame >> with >> a broken weld-nut and a piece of bolt sticking out. Not good. Plasma >> cutter >> wasn't working. We decided to cut a hole in the frame extension welded on >> where the weld-nut resided, pull it out, and weld a new piece in place >> with >> a new weld nut. Without the plasma cutter, we resorted to an air-driven >> die >> grinder. Two hours later, the patch was welded into place. The remainder >> of >> the rear was pretty uneventful, but I had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >> flush >> with the bracket, put a pickle fork between the braket and used a BFH to >> make a gap and rip the control arm out. Then, for some reason, on the >> install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute >> nightmare. >> I don't think that it had anything to do with Rubicon's parts, design, or >> quality. The kit with the DT3 shocks rides well and smooth. Most of the >> parts were correct and fit well. I did have to bore out one side of one >> lower control arm axle end bolt hole. I also re-drilled the track bar >> mount. >> >> To make matters worse, my spare car that i was going to give to someone >> whom >> had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl |
Re: Lift install NIGHTMARE
Cool. I was able to torch most of them, but suffered a bad burn on one of my
fingers from molten bushing. Carl "Mike Romain" <romainm@sympatico.ca> wrote in message news:437F6C20.433A2877@sympatico.ca... >I feel for you! When I took my CJ7 apart only one bolt came out of the > tub, the rest spun or snapped. I took my spring lift job to a spring > shop! They torched the suckers apart. > > Mike > 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00 > 88 Cherokee 235 BFG AT's > Canadian Off Road Trips Photos: Non members can still view! > Aug./05 http://www.imagestation.com/album/in...?id=2120343242 > (More Off Road album links at bottom of the view page) > > Carl wrote: >> >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >> 91 >> XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, >> a >> welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 >> with a torch and muscle them out. The last, the passenger side front leaf >> spring bolt.. sheared off in the bushing AND broke the weld-nut inside >> the >> frame. Yes, I broke them both. We had to bend the spring hangar and cut >> the >> spring eye in half. THEN we had to cut the bolt - it turned out the >> bushing's sleeve had siezed to the bolt. Now we had a hole in the frame >> with >> a broken weld-nut and a piece of bolt sticking out. Not good. Plasma >> cutter >> wasn't working. We decided to cut a hole in the frame extension welded on >> where the weld-nut resided, pull it out, and weld a new piece in place >> with >> a new weld nut. Without the plasma cutter, we resorted to an air-driven >> die >> grinder. Two hours later, the patch was welded into place. The remainder >> of >> the rear was pretty uneventful, but I had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >> flush >> with the bracket, put a pickle fork between the braket and used a BFH to >> make a gap and rip the control arm out. Then, for some reason, on the >> install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute >> nightmare. >> I don't think that it had anything to do with Rubicon's parts, design, or >> quality. The kit with the DT3 shocks rides well and smooth. Most of the >> parts were correct and fit well. I did have to bore out one side of one >> lower control arm axle end bolt hole. I also re-drilled the track bar >> mount. >> >> To make matters worse, my spare car that i was going to give to someone >> whom >> had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl |
Re: Lift install NIGHTMARE
Cool. I was able to torch most of them, but suffered a bad burn on one of my
fingers from molten bushing. Carl "Mike Romain" <romainm@sympatico.ca> wrote in message news:437F6C20.433A2877@sympatico.ca... >I feel for you! When I took my CJ7 apart only one bolt came out of the > tub, the rest spun or snapped. I took my spring lift job to a spring > shop! They torched the suckers apart. > > Mike > 86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00 > 88 Cherokee 235 BFG AT's > Canadian Off Road Trips Photos: Non members can still view! > Aug./05 http://www.imagestation.com/album/in...?id=2120343242 > (More Off Road album links at bottom of the view page) > > Carl wrote: >> >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my >> 91 >> XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, >> a >> welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 >> with a torch and muscle them out. The last, the passenger side front leaf >> spring bolt.. sheared off in the bushing AND broke the weld-nut inside >> the >> frame. Yes, I broke them both. We had to bend the spring hangar and cut >> the >> spring eye in half. THEN we had to cut the bolt - it turned out the >> bushing's sleeve had siezed to the bolt. Now we had a hole in the frame >> with >> a broken weld-nut and a piece of bolt sticking out. Not good. Plasma >> cutter >> wasn't working. We decided to cut a hole in the frame extension welded on >> where the weld-nut resided, pull it out, and weld a new piece in place >> with >> a new weld nut. Without the plasma cutter, we resorted to an air-driven >> die >> grinder. Two hours later, the patch was welded into place. The remainder >> of >> the rear was pretty uneventful, but I had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to >> flush >> with the bracket, put a pickle fork between the braket and used a BFH to >> make a gap and rip the control arm out. Then, for some reason, on the >> install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute >> nightmare. >> I don't think that it had anything to do with Rubicon's parts, design, or >> quality. The kit with the DT3 shocks rides well and smooth. Most of the >> parts were correct and fit well. I did have to bore out one side of one >> lower control arm axle end bolt hole. I also re-drilled the track bar >> mount. >> >> To make matters worse, my spare car that i was going to give to someone >> whom >> had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl |
Re: Lift install NIGHTMARE
did you have plenty of beer?
"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my 91 > XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, a > welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut the > spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame with > a broken weld-nut and a piece of bolt sticking out. Not good. Plasma cutter > wasn't working. We decided to cut a hole in the frame extension welded on > where the weld-nut resided, pull it out, and weld a new piece in place with > a new weld nut. Without the plasma cutter, we resorted to an air-driven die > grinder. Two hours later, the patch was welded into place. The remainder of > the rear was pretty uneventful, but I had to loose the crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to flush > with the bracket, put a pickle fork between the braket and used a BFH to > make a gap and rip the control arm out. Then, for some reason, on the > install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute nightmare. > I don't think that it had anything to do with Rubicon's parts, design, or > quality. The kit with the DT3 shocks rides well and smooth. Most of the > parts were correct and fit well. I did have to bore out one side of one > lower control arm axle end bolt hole. I also re-drilled the track bar mount. > > To make matters worse, my spare car that i was going to give to someone whom > had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl > > |
Re: Lift install NIGHTMARE
did you have plenty of beer?
"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my 91 > XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, a > welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut the > spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame with > a broken weld-nut and a piece of bolt sticking out. Not good. Plasma cutter > wasn't working. We decided to cut a hole in the frame extension welded on > where the weld-nut resided, pull it out, and weld a new piece in place with > a new weld nut. Without the plasma cutter, we resorted to an air-driven die > grinder. Two hours later, the patch was welded into place. The remainder of > the rear was pretty uneventful, but I had to loose the crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to flush > with the bracket, put a pickle fork between the braket and used a BFH to > make a gap and rip the control arm out. Then, for some reason, on the > install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute nightmare. > I don't think that it had anything to do with Rubicon's parts, design, or > quality. The kit with the DT3 shocks rides well and smooth. Most of the > parts were correct and fit well. I did have to bore out one side of one > lower control arm axle end bolt hole. I also re-drilled the track bar mount. > > To make matters worse, my spare car that i was going to give to someone whom > had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl > > |
Re: Lift install NIGHTMARE
did you have plenty of beer?
"Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... > This is long, but it details the problems my friend Shaun and I had > installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my 91 > XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, a > welder, and plenty of drills, grinders, and other power tools. > > We started on Friday at 3pm. We didn't leave the shop untill Saturday at > 3am. Let me tell you, I have a new respect for stuck bolts. > > All four rear leaf spring bolts were siezed. I was able to heat 3 of the 4 > with a torch and muscle them out. The last, the passenger side front leaf > spring bolt.. sheared off in the bushing AND broke the weld-nut inside the > frame. Yes, I broke them both. We had to bend the spring hangar and cut the > spring eye in half. THEN we had to cut the bolt - it turned out the > bushing's sleeve had siezed to the bolt. Now we had a hole in the frame with > a broken weld-nut and a piece of bolt sticking out. Not good. Plasma cutter > wasn't working. We decided to cut a hole in the frame extension welded on > where the weld-nut resided, pull it out, and weld a new piece in place with > a new weld nut. Without the plasma cutter, we resorted to an air-driven die > grinder. Two hours later, the patch was welded into place. The remainder of > the rear was pretty uneventful, but I had to loose the crappy tow hitch. > > What is it with this passenger side? Lower control arm, upper bolt. Same > thing. Seized sleeve in the bushing. Ridiculous. We ground it down to flush > with the bracket, put a pickle fork between the braket and used a BFH to > make a gap and rip the control arm out. Then, for some reason, on the > install of the new control arms, the bolt I had just taken out of the > driver's side lower control arm frame end mount wouldn't go back thru the > frame. None of them would. Scrounge up another bolt.. > > So we installed a longer rear brake line, and I tried to re-position the > driver's side front brake line mount after I straightened the tubes as > outlined by RE. No dice. Either way, we need to bleed the brakes. This is > about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. > Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 > miles with my E-brake. > > This RE 3.5" lift was a FIGHT every step of the way, an absolute nightmare. > I don't think that it had anything to do with Rubicon's parts, design, or > quality. The kit with the DT3 shocks rides well and smooth. Most of the > parts were correct and fit well. I did have to bore out one side of one > lower control arm axle end bolt hole. I also re-drilled the track bar mount. > > To make matters worse, my spare car that i was going to give to someone whom > had their house burn down.... it was stolen last night! > > All I can say is..wow.. > > Carl > > |
Re: Lift install NIGHTMARE
Just remember to tighten it first. I learned long ago a breaker bar
was a complete waste of time. And be prepared, I always buy a new set first, so I could just use oxyacetylene. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > Bill - > We had a big ass 3/4" drive impact wrench that could spin my arms off. > Hopefully it comes apart easier next time. > > Carl |
Re: Lift install NIGHTMARE
Just remember to tighten it first. I learned long ago a breaker bar
was a complete waste of time. And be prepared, I always buy a new set first, so I could just use oxyacetylene. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > Bill - > We had a big ass 3/4" drive impact wrench that could spin my arms off. > Hopefully it comes apart easier next time. > > Carl |
Re: Lift install NIGHTMARE
Just remember to tighten it first. I learned long ago a breaker bar
was a complete waste of time. And be prepared, I always buy a new set first, so I could just use oxyacetylene. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > Bill - > We had a big ass 3/4" drive impact wrench that could spin my arms off. > Hopefully it comes apart easier next time. > > Carl |
Re: Lift install NIGHTMARE
That's why we use welder's gloves, next lesson will be always cover
your ears. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > Cool. I was able to torch most of them, but suffered a bad burn on one of my > fingers from molten bushing. > > Carl |
Re: Lift install NIGHTMARE
That's why we use welder's gloves, next lesson will be always cover
your ears. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > Cool. I was able to torch most of them, but suffered a bad burn on one of my > fingers from molten bushing. > > Carl |
Re: Lift install NIGHTMARE
That's why we use welder's gloves, next lesson will be always cover
your ears. God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ Carl wrote: > > Cool. I was able to torch most of them, but suffered a bad burn on one of my > fingers from molten bushing. > > Carl |
Re: Lift install NIGHTMARE
I think that's how we measure a job, like Doug's pages:
http://members.cox.net/wilsond/front...way/index.html God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ "J. Sprauer" wrote: > > did you have plenty of beer? |
Re: Lift install NIGHTMARE
I think that's how we measure a job, like Doug's pages:
http://members.cox.net/wilsond/front...way/index.html God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ "J. Sprauer" wrote: > > did you have plenty of beer? |
Re: Lift install NIGHTMARE
I think that's how we measure a job, like Doug's pages:
http://members.cox.net/wilsond/front...way/index.html God Bless America, Bill O|||||||O mailto:-------------------- http://www.----------.com/ "J. Sprauer" wrote: > > did you have plenty of beer? |
Re: Lift install NIGHTMARE
i like that!
"L.W. (ßill) ------ III" <----------@cox.net> wrote in message news:437FA05A.3BFDF676@cox.net... > I think that's how we measure a job, like Doug's pages: > http://members.cox.net/wilsond/front...way/index.html > God Bless America, Bill O|||||||O > mailto:-------------------- http://www.----------.com/ > > "J. Sprauer" wrote: > > > > did you have plenty of beer? |
Re: Lift install NIGHTMARE
i like that!
"L.W. (ßill) ------ III" <----------@cox.net> wrote in message news:437FA05A.3BFDF676@cox.net... > I think that's how we measure a job, like Doug's pages: > http://members.cox.net/wilsond/front...way/index.html > God Bless America, Bill O|||||||O > mailto:-------------------- http://www.----------.com/ > > "J. Sprauer" wrote: > > > > did you have plenty of beer? |
Re: Lift install NIGHTMARE
i like that!
"L.W. (ßill) ------ III" <----------@cox.net> wrote in message news:437FA05A.3BFDF676@cox.net... > I think that's how we measure a job, like Doug's pages: > http://members.cox.net/wilsond/front...way/index.html > God Bless America, Bill O|||||||O > mailto:-------------------- http://www.----------.com/ > > "J. Sprauer" wrote: > > > > did you have plenty of beer? |
Re: Lift install NIGHTMARE
We only had a 12 pack. :-(
Carl "J. Sprauer" <jsprauer2000@yahoo.com> wrote in message news:N5Nff.23070$dO2.8004@newssvr29.news.prodigy.n et... > did you have plenty of beer? > > > > "Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message > news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my > 91 >> XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, >> a >> welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 >> with a torch and muscle them out. The last, the passenger side front leaf >> spring bolt.. sheared off in the bushing AND broke the weld-nut inside >> the >> frame. Yes, I broke them both. We had to bend the spring hangar and cut > the >> spring eye in half. THEN we had to cut the bolt - it turned out the >> bushing's sleeve had siezed to the bolt. Now we had a hole in the frame > with >> a broken weld-nut and a piece of bolt sticking out. Not good. Plasma > cutter >> wasn't working. We decided to cut a hole in the frame extension welded on >> where the weld-nut resided, pull it out, and weld a new piece in place > with >> a new weld nut. Without the plasma cutter, we resorted to an air-driven > die >> grinder. Two hours later, the patch was welded into place. The remainder > of >> the rear was pretty uneventful, but I had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to > flush >> with the bracket, put a pickle fork between the braket and used a BFH to >> make a gap and rip the control arm out. Then, for some reason, on the >> install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute > nightmare. >> I don't think that it had anything to do with Rubicon's parts, design, or >> quality. The kit with the DT3 shocks rides well and smooth. Most of the >> parts were correct and fit well. I did have to bore out one side of one >> lower control arm axle end bolt hole. I also re-drilled the track bar > mount. >> >> To make matters worse, my spare car that i was going to give to someone > whom >> had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl >> >> > > |
Re: Lift install NIGHTMARE
We only had a 12 pack. :-(
Carl "J. Sprauer" <jsprauer2000@yahoo.com> wrote in message news:N5Nff.23070$dO2.8004@newssvr29.news.prodigy.n et... > did you have plenty of beer? > > > > "Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message > news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my > 91 >> XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, >> a >> welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 >> with a torch and muscle them out. The last, the passenger side front leaf >> spring bolt.. sheared off in the bushing AND broke the weld-nut inside >> the >> frame. Yes, I broke them both. We had to bend the spring hangar and cut > the >> spring eye in half. THEN we had to cut the bolt - it turned out the >> bushing's sleeve had siezed to the bolt. Now we had a hole in the frame > with >> a broken weld-nut and a piece of bolt sticking out. Not good. Plasma > cutter >> wasn't working. We decided to cut a hole in the frame extension welded on >> where the weld-nut resided, pull it out, and weld a new piece in place > with >> a new weld nut. Without the plasma cutter, we resorted to an air-driven > die >> grinder. Two hours later, the patch was welded into place. The remainder > of >> the rear was pretty uneventful, but I had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to > flush >> with the bracket, put a pickle fork between the braket and used a BFH to >> make a gap and rip the control arm out. Then, for some reason, on the >> install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute > nightmare. >> I don't think that it had anything to do with Rubicon's parts, design, or >> quality. The kit with the DT3 shocks rides well and smooth. Most of the >> parts were correct and fit well. I did have to bore out one side of one >> lower control arm axle end bolt hole. I also re-drilled the track bar > mount. >> >> To make matters worse, my spare car that i was going to give to someone > whom >> had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl >> >> > > |
Re: Lift install NIGHTMARE
We only had a 12 pack. :-(
Carl "J. Sprauer" <jsprauer2000@yahoo.com> wrote in message news:N5Nff.23070$dO2.8004@newssvr29.news.prodigy.n et... > did you have plenty of beer? > > > > "Carl" <carlsaiyed@REMOVE.hotmail.com> wrote in message > news:CJudnbpZOKfdwOLeRVn-tg@comcast.com... >> This is long, but it details the problems my friend Shaun and I had >> installing a Rubicon 3.5" Super-Ride system (With full rear sprins) on my > 91 >> XJ Laredo. Luckily, we had a vehicle lift, a big air gun, plenty of air, >> a >> welder, and plenty of drills, grinders, and other power tools. >> >> We started on Friday at 3pm. We didn't leave the shop untill Saturday at >> 3am. Let me tell you, I have a new respect for stuck bolts. >> >> All four rear leaf spring bolts were siezed. I was able to heat 3 of the >> 4 >> with a torch and muscle them out. The last, the passenger side front leaf >> spring bolt.. sheared off in the bushing AND broke the weld-nut inside >> the >> frame. Yes, I broke them both. We had to bend the spring hangar and cut > the >> spring eye in half. THEN we had to cut the bolt - it turned out the >> bushing's sleeve had siezed to the bolt. Now we had a hole in the frame > with >> a broken weld-nut and a piece of bolt sticking out. Not good. Plasma > cutter >> wasn't working. We decided to cut a hole in the frame extension welded on >> where the weld-nut resided, pull it out, and weld a new piece in place > with >> a new weld nut. Without the plasma cutter, we resorted to an air-driven > die >> grinder. Two hours later, the patch was welded into place. The remainder > of >> the rear was pretty uneventful, but I had to loose the crappy tow hitch. >> >> What is it with this passenger side? Lower control arm, upper bolt. Same >> thing. Seized sleeve in the bushing. Ridiculous. We ground it down to > flush >> with the bracket, put a pickle fork between the braket and used a BFH to >> make a gap and rip the control arm out. Then, for some reason, on the >> install of the new control arms, the bolt I had just taken out of the >> driver's side lower control arm frame end mount wouldn't go back thru the >> frame. None of them would. Scrounge up another bolt.. >> >> So we installed a longer rear brake line, and I tried to re-position the >> driver's side front brake line mount after I straightened the tubes as >> outlined by RE. No dice. Either way, we need to bleed the brakes. This is >> about 230am. Both rear brake bleeders BROKE OFF. Try the pedal. NOTHING. >> Said forget it, let a shop fix the brakes. Cleaned up and drove home 20 >> miles with my E-brake. >> >> This RE 3.5" lift was a FIGHT every step of the way, an absolute > nightmare. >> I don't think that it had anything to do with Rubicon's parts, design, or >> quality. The kit with the DT3 shocks rides well and smooth. Most of the >> parts were correct and fit well. I did have to bore out one side of one >> lower control arm axle end bolt hole. I also re-drilled the track bar > mount. >> >> To make matters worse, my spare car that i was going to give to someone > whom >> had their house burn down.... it was stolen last night! >> >> All I can say is..wow.. >> >> Carl >> >> > > |
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