Stuck bolt in end of leaf pack

[2TimingTom]

I'm trying to install my Warrior 153 shackles. I sprayed down the 4 bolts a couple days ago with power steering fluid (ATF and acetone is suppose to work as well, but the original test was actually done with PS fluid and acetone). I got 3 of the 4 to the point where they will come out- but the one right next to the exhaust pipe won't budge. I'm guessing 15 years and 134,000 miles of heat and

I've tried:
3 lb sledge- but a lot of the force is absorbed by wiggle in the shackle and probably the rubber in the bushing.

Turning the bolt- both tightening and loosening.

Loosening the bolt while hitting bushing part of the leaf pack with the hammer

Have not yet tried due to time constraints:
Torch- how much heat can the bushing take? Heating the bolt head will make the bolt expand- I need it to shrink.

Air hammer


I sprayed it down again this morning before I left for work (this is one reason why I love having a DD).

Any ideas?

 

[colintrax]

Have you tried a 3 jaw puller? Just use the center bolt to push on the bolt.

 

[Carguy3J]

I'm trying to install my Warrior 153 shackles. ......... I'm guessing 15 years and 134,000 miles of heat and ..........
Any ideas?

I think it is time for new springs. I would be surprised if you didn't have the "gangster lean" that 2ng gen Explorers are known for. Even if the leafs themselves aren't somehow fatigued, the rubber bushings are surley shot. Adding shackles/lifts will only put more force/stress on them, as the vehicle's weight will have more leverage on the bushings/springs. Also, the higher center of gravity will impart greater side loads on the rubber when cornering.

Buy (2) new springs. They come with all new bushings already installed. You should be able to get all new grade 8 nuts/bolts at a good hardware store. (Forget Home Depot). Oddly enough, Sears Hardware stores sometimes have a good selection of hard-to-find hardware.

 

[Anime]

The easiest way to get the stuck bolt off is to use the weight of the vehicle to turn it.

Jack up the frame on the rear passenger side.

Re-install the upper bolt on the shackle, but under the frame, not in the frame bushing.

Make sure the flange on the shackle is leveraging against the tab on the bolt head of the stock bolt that's stuck.

Get out of the way, and slowly lower the vehicle onto the shackle, which should turn and eventually pop the bolt loose.

If the bolt supports the weight rather than turning, use some more penetrating oil, and try lowering the vehicle quicker, until either the bolt pops lose or something breaks.


Worst case, the tab cuts into the shackle if it's so rusted it's thin and weak, or the bolt twists the head half off and you have to try to pound the other end out with a punch.


I would suggest getting new bushings for the leaf springs. Energy Suspension makes a good polyurethane set.

You can swap the leaf springs left to right to level out the sag, better even than new springs.