This week I am buying new wheels and tires for Stephanie’s Jeep Cherokee Sport (XJ if you will). I figured that if I am spending all that money on wheels, tires, and an alignment this would be a good time to deal with it’s ancient suspension. The XJ was rocking and rolling down the streets like James Brown, so it was easy to determine it needed new shocks.
Saturday morning I get up bright an early and head to the auto parts store. I pick up new front and rear shocks and a new steering stabilizer. Nothing fancy just Monroe Gasmatic — equal to or just a bit nicer than OEM. Remember, this car only gets driven about 50 miles a week so it doesn’t need anything super nice.
Back at home I jack up the car, pull the front wheels and go to work on the front struts. All goes relatively well except the top bolt on the drivers side is damaged so I have to cut it off. No big deal though. JT shows up around this time and starts helping out on the other side of the car. In pretty short order we have the new front struts in. This is going well. Next up the steering stabilizer.
This gets a bit more difficult. One side pops right off, but the other side is attached to a stud that goes through the steering linkage and is bolted down on the other side. We try and get that stud out but don’t have any luck. We decide it is time for lunch so we grab some food and then stop by JTs to get his propane torch. Heating up the linkage doesn’t help loosen the bolt at all. After looking at it a bit, it hits JT. This looks just like the end of a tie rod, maybe a tie rod puller will work. Back to his place to get his tie rod puller, and two minutes later the front stabilizer is removed and the new one is in place. Right tool…
JT heads off to work about now, and I start work on the rears. I get the lower connection on the passenger side rear shock off, and attempt to remove the two bolts holding the top to the frame. SNAP! The bolt shears off in the frame. Shit. The shock has to come off for me to deal with that, so I try the second bolt. SNAP! Shit. I figure I should go all in at this point and try the other shock. Now I have four bolts sheared off in the frame of the jeep. My night just got really long.
I head to the hardware store and buy new bolts, and the tools to either extract these bolts or drill them out and retap. After I give my penetrating oil a couple of hours to soak, I try the extractor. I drill through the bolt, turn in the extractor, and it bites beautifully. I turn on it, and the bolt doesn’t budge. Try again. SNAP! Shit. Now I am done for. I try and drill out the broken extractor but my drill bits barely scratch it. I head upstairs thinking I am going to have to take this to a mechanic to get those bolts out.
After reading online a bit, I discover that this happens to a very large number of XJ owners when attempting to work on the rear suspension. Then I run across this page
Accessing the rear bolts from above
Basically it details how to cut access panels from the body above to get at the bolts. This is exactly what I need. I head back down to the garage, get out my trusty dremel and start cutting into the jeep. In short order I am looking down at the nuts welded to the frame. A while longer cutting off the welds and I break the bolt loose and am looking at a clean whole that I can attach my suspension to. Awesome. It is now 11pm, and with my proof of concept I call it a night.
The next morning I head to the hardware store to get some new nuts and bolts for mounting the rear shocks, and more cutting discs for my dremel. An hour later the new suspension is installed. I paint the body on the edges where I cut, throw down a couple layers of dynamat to seal it, and roll the carpeting back in place.
I take it for a spin and everything feels much better. The jeep is much more stable, doesn’t roll as much when turning, and doesn’t bounce and jostle so much after hitting a bump. The suspension feedback through the steering column also feels more damped. That might just be psychological though.
This job that I expected to take a couple of hours in the end took about 12. Why does that always seem to be the case when I am working on cars…. Oh well. Everything is installed and works and it only cost me about $200 in parts and tools.
gnubbs