Shocks replacement gone bad : frame repair needed

[dpom]

Shocks replacement gone bad

I just decide to replace the stock shocks on my 94 XLT with 132k. I figured it was time. I bought 4 Gabriel Gas Ryder VSTs from Autozone for about $100 total.

We sprayed PB blast on all the rusted fasteners. After about a half hour, (not long enough) we started with the fronts after reading about the backs being a harder job. The top nut came off without too much hassle, the bottom however was on really tight. We used a breaker bar and ended up twisting the bolt right off the frame.

So I went to the other side hit it with more PB and took a torch to it. The nut started to come off with the breaker bar but when there was a few threads left to go that one twisted off too. Great, 2 for 2.

Moving on to the rear. The top nuts were crumbling with rust. The only way I could get those off was with a nut extractor set. I used a wedge shaped piece of wood to give the socket wrench pressure down on the nut. So I tried to get the bottom fastener off and the breaker bar broke that bolt too. Awesome, 3 for 3. We ended up having to skil saw the bolt off of the shock mount because it had rusted itself to the inner shock sleave so badly. Gotta love those finesse tools.

The fourth shock actually came off without breaking.

The Rears:

I am a little concerned with the front shocks though, since they aren't really even attached. They are basically sitting on what's left of the mount. I had to drive 2 hours home after the install, so I did what I could to secure them with telephone ties.

pic:

Close up1:

Close up2:

The ties actually keep the shock pretty sturdy. It doesn't move when you shake it with your hand, and it hasnt moved over the 150 miles I have driven with it like this.

What I need to know is how much is this going to cost to fix? Should I take this to a welder or a mechanic? Is there way I any can fix this myself without welding? It was suggested that I could try to drill into the mount and then put a screw into it with a washer.

Any suggestions? Thanks.

 

[410Fortune]

This is a VERY common problem.
If you search this site you will find it is covered.

I believe you have two options:
1. drill out the bolt and radius arm and run a bolt through it, this will work fine
2. Replace the radius arm

Obviously cutting the bolt off, drilling a hole, and running a new grade 5 or 8 bolt through the radius arm is the easier and cheaper method.

I however have not ever run into this problem so dont qoute me on those. Do a search and see what others have done to solve this.
I believe Ford actually got wise to this eventually and changed hte design of the radius arms, but again I may just be blowing smoke, this is from memory.

 

[Maniak]

I wouldn't say this is a common problem, but it does happen. Its worse in the rustbelt..

I had one mount break on our '92.. I went to desert Rat and they welded a new one on for me for $<50 total..

A good shop should be able to fix it for you pretty cheap.. (go to a good 4x4 shop, not some place that has no idea what 4x4 is for).

~Mark

 

[410Fortune]

ok okay so we have a different opinion of common I guess, but in the many years I have been on this board I have seen this topic come up quite a few times. I should edit my post to say that??

hahaha
regardless it happens, I like the zip tie fix, zip ties can fix anything.

 

[sncwfo99]

The same thing happened to me when I changed my shocks. I drilled the mounts out about an inch and welded stainless studs back in. This was almost a year ago now and everything is holding up just fine.

 

[Maniak]

no.. don't edit.. I was thinking common as in things like the inside door handle on the drivers side breaking, the center armrest breaking, auto trannies dying before 200k miles.. things like that..

I would say though, I've heard of more front/lower shock mounts breaking on ford explorers than I have other vehicles... (ok, breaking when working on them)..

~Mark

 

[410Fortune]

Yes now I agree those are "Super common" hahaha