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Sway bar nuts inside frame snapped

Tiny
RENNY DECKERT
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  • 2003 JEEP GRAND CHEROKEE
  • 4.0L
  • V6
  • 4WD
  • AUTOMATIC
  • 250,000 MILES
I'm replacing the sway bar on my front end, and the welded nuts inside the frame for the bushing bolts snapped from the frame, so now the bolts are just spinning. Am I better off just grinding the heads off the bolts, pushing them into the frame, and then using self-tapping bolts to reinstall the new sway bar?
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Tuesday, May 12th, 2020 AT 1:31 PM

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Tiny
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You have two options. First if I remember correctly the end of this boxed frame rail is opened. So you would have to remove the front bumper and then you will have access to the nut. What I can't remember is if this nut is before or after the bend in the frame. From the picture it looks like it is in front of it. If you get a picture of the front frame rails, I will be able to tell better.

The other option and easier one is to cut a small access hole in the frame rail to access the nut and weld in a new nut and then weld a plate back on the frame rail. You could do the cutting with a cut off wheel and then it is pretty cheap to have someone weld this back up as most don't have welders.

I know this is not this is not the most desirable situation but unfortunately those nuts are a pain when they break loose.

Let me know if you have questions.

Thanks
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Tuesday, May 12th, 2020 AT 1:46 PM
Tiny
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You are absolutely correct. The frame rails are open behind the bumper when I peeked behind it. I think I will attempt that route. I could cut a hole open in the frame, but there is not much room on the driver side to do it.
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Tuesday, May 12th, 2020 AT 2:08 PM
Tiny
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Actually, going through the front opening does seem like it may be a problem. There is a plate blocking access to the rear bolts. Can this plate be removed to give access to the rear bolt?
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Tuesday, May 12th, 2020 AT 2:31 PM
Tiny
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Yeah. I couldn't remember if you had access all the way back to them.
Unfortunately I would not remove that because I am not sure how you would get it back on, but I think we can see why that nut broke loose. Clearly there is a corrosion issue inside the rail.

One other option is to cut just a small hole to get a box end wrench in and hold the nut. I don't know what size it is but I know people that have done it. This is clearly not a fix but at least it will get the bolt out and the new one back in. Next time you may need to take it off it will do the same thing but honestly it is unlikely to need to do that for quite some time. Just another thought.
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Tuesday, May 12th, 2020 AT 6:10 PM
Tiny
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The plate looks to be held on by a single nut threaded over a welded stud. I'm not sure what purpose the plate serves other than the sway bar bushing being welded to it. There is no such plate on the passenger side, only the driver side. Not sure it would even serve any purpose going back on. The sway bar bolt should still go right the frame and be able to thread into the new nut. Bad idea? I just hate to cut into the frame, only to have someone do a bad job welding a plate over the hole and me never notice it fall off, compromising the integrity of the frame.
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Tuesday, May 12th, 2020 AT 6:25 PM
Tiny
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Understood. I looked at it for quite a while and was not sure what it was for either. Clearly it served a purpose but if it were me, I would give it a try to remove it and see what happens. However, it is hard for me to recommend others do that because I don't want to get you into a worse position. However, since you broke that ice, I would go for it. It is the least intrusive way to try and solve this issue.
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Tuesday, May 12th, 2020 AT 6:42 PM
Tiny
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I like it. I'm gonna give it a go in the morning. It really does look like its only purpose is holding that welded nut, which I don't understand because the passenger side has no such plate. Then again, I've seen weirder things that made no sense. One of those things to get someone to take a car to a dealer shop when something goes wrong. Thank you very much for all your help. I greatly appreciate it!
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Tuesday, May 12th, 2020 AT 6:51 PM
Tiny
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Haha. Sounds great. Please let us know what happens when you get it wrapped up. Thanks for the update.
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Wednesday, May 13th, 2020 AT 4:57 PM
Tiny
STEVE W.
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It looks like it is spot welded to something as well as bolted. It might be the plate for the steering box as that is very close to that spot.
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Wednesday, May 13th, 2020 AT 5:09 PM
Tiny
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That plate was indeed spot welded. That bolt was threaded onto a plastic clip coming from underneath. The clip served no purpose that I'm aware as I never pulled anything away from it. May have been for an underside cover that isn't there anymore. I managed to get the passenger bolts off, but it looks like cutting into the frame is the only option on the driver side. I'm just going to cut the head of the bolt off if it gives me trouble, and then I'll be able to use the cut hole in the frame to thread the nut onto the new bolt. Unless there's another option that doesn't involve cutting the frame, but it doesn't look like it.
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Wednesday, May 13th, 2020 AT 5:29 PM
Tiny
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I will contact one of my dealers tomorrow and ask if they have any other tricks but that is the only one I am aware of. I will update this again tomorrow.
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Wednesday, May 13th, 2020 AT 8:04 PM
Tiny
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Thank you very much.
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Wednesday, May 13th, 2020 AT 8:27 PM
Tiny
STEVE W.
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This is for the sway bar bushing clamp correct? Cut the head off the bolt knock the old piece out of the way. Now get a steel rivnut plusnut insert in the correct size and install it into the frame. No cutting or fuss. Installed correctly it will be as strong as the welded nut and much faster.
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Wednesday, May 13th, 2020 AT 9:52 PM
Tiny
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Would have never thought of this. Thank you very much. That is exactly what I will do. The bolt will forever rattle around inside the frame, but oh well. Better/safer than cutting a hole in the frame I'd say.
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Wednesday, May 13th, 2020 AT 11:32 PM
Tiny
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That is a good idea. Thanks Steve. Let us know how you make out. Thanks
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Thursday, May 14th, 2020 AT 6:44 PM

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