Bolt Buster
In trying to upgrade my '99 XJ's suspension, I was installing sway-bar disconnects. However, the bottom Torx head bolts seem to be extremely stubborn. I've used plenty of WD-40 to loosen them, and I've also heated them up, but they will not budge. Any ideas?Scott SpanglVia e-mail
I'd swap from WD-40 to a better penetrating oil like Justice Brothers JB-80 or PB Blaster. Let it soak for a few days, spraying one or two times per day. Make sure you're using the correct Torx bit so you don't strip the head. Then try a big 11/42-inch impact air wrench on it. The shock of the impact should help break it free. If that doesn't do it, try a breaker bar with a length of pipe for more leverage.
I think you're talking about the lower sway-bar link mounts-the ones that go horizontally through the metal tabs that come off the front of the axlehousing? If you're not reusing the stock sway-bar links, you can carefully use a 4-inch angle grinder to remove the head of the bolt, then just knock them off.
Stuck Stick
My TJ is on jackstands at my father-in-law's. We spent some time replacing the clutch, but then ended up spending the next several hours trying to separate the transmission and transfer case from the engine. There is a bolt linking the assembly and engine on top, and it's damaged from the previous owner. We spent quite some time grinding it down. We are still having difficulty parting it from the engine. Do you have any tips or tricks that you can send our way?Mike PetrarcaMurietta, California
First, verify that the rest of the bellhousing bolt holes are free and clear. You didn't leave any bolts in there, did you? There are two 12-point bolts on the top of the bellhousing. It's difficult to get a socket on them. If you've already ground the bolt, then you're committed to finishing the job.
I'd use a small die grinder with a carbide bit to fully remove the bolt head flush with the bellhousing. This should let you slide the assembly back far enough to clear. If the bellhousing hits the firewall before clearing the bolt, you'll need to hook the engine up to a hoist and unbolt the engine mounts. Carefully slide the whole assembly forward about an inch (any more and you may damage A/C and fuel lines). Make sure the tranny/T-case are supported from underneath. Then with the extra clearance, you should be able to slide the tranny/T-case off. You may need to use one or two long pry bars to gently coax the input shaft from the pilot bushing. If it's boogered, it won't let the tranny cleanly come off sometimes. Don't use too much force.