Getting this old track bar out of the XJ

[bradleyheathhays]

I developed a bit of death wobble in the old 96er recently and traced it to the driver side connection of my track bar, so I'm in the middle of getting it out. I've been soaking the passenger side connection in the picture below with PB for a while now, and it's still distressingly hard to turn. I can get the red bolt head to turn some using 4-5" worth of cheater bar on my 3/8" ratchet, but only until the yellow nut tab reaches it's limit of travel within the rectangular hole it protrudes through. I keep doing PB soaks, torches followed by cold water dousing cycles, but it's not getting any easier to turn at all. The nut is rotating with the bolt because the tab moves when I turn the bolt, so the nut is not what's holding it up. My best idea is that the bolt has rusted to the metal sleeve in the track bar bushing and that sleeve is rotating with the bolt, held by the friction against the rubber. I haven't even tried to rotate the bolt past where the nut tab comes in contact with it's limits as I'm almost putting enough torque on it to twist the head off already.

Any advice on working this thing?

Also, say the bolt head were to snap off. What would you do to get the bolt out? My only idea would be to try to push the bolt through from the head side with an awl or something smaller than the bolt diameter, then try to get an oscillating cutter up into that window on the right and piece by piece cut the end of the bolt off until it all comes through. Thoughts?

 

[TerryMason]

That is a captive nut. Without that flag / metal bar connected to it, it's much more difficult to get started. Here's what it looks like

You're right that the bolt is probably rusted to the bushing sleeve. If it were me, I would throw my impact on the bolt and just send it. You could keep up the penetrating oil for a few days - that would likely help.

If the bolt head snaps off, you may be able to get a cutoff wheel, sawzall, or multitool between the trackbar and the axle tube to cut that side of the bolt off as well. Looks like that bushing is toast, so no need to try and preserve it.

I ended up drilling my trackbar hole larger, and putting in a larger bolt with a standard nut on the end. I've found that a flare nut wrench is small enough to fit in that opening and hold the nut while I tighten (a standard wrench wouldn't fit in that spot on my TJ).

 

[JPNinPA]

I find it hard to believe the nut rusted to the sleeve. The bolt is a lot smaller than the sleeve. I typically tell people to get the largest bolt to minimize potential movement. Heat the bolt and smack it with a hammer or pneumatic hammer.
If the flag broke loose you should be able to get a box end wrench in there.


Never look down on anyone unless you are helping them up - Jesse Jackson