Sway bar bushing nuts are gone!

[Alluvialfan]

I went to replace the sway bar bushings on my stock 97 sport, and the threads disappeared on the cross member.
#1 )How can this be fixed.
#2 )How can I make my Xploder as bad ass as the stuff I've seen here?

 

[RangerX]

1. new/longer bolt w/nut.
2. search and read!

 

[swshawaii]

Threads disappeared? If the front sway bar bracket holes are stripped, try chasing the threads or re-tap one larger size.
The rear bracket bolts use extruded u-nuts that are replaceable or a regular or lock nut and washer can be used instead.

http://www.explorerforum.com/forums/showthread.php?t=335575

 

[Alluvialfan]

I think the only threads were on nuts welded to the inside of the cross member, apparently as it was being manufactured. The holes are .550" diameter, and the bolt has a .465" major diameter.
I can't reach the backside of the hole to replace the nut. The cross member is too thin to be threaded directly.
BTW, only 1 side is lost, so I can compare. But the effect is the same. It gets pretty wobbly, side to side, on the highway.

 

[RangerX]

Alluvial, I'm moving your thread to the 2nd Gen forum for better exposure.
Is this on the front or rear sway bar?

 

[Alluvialfan]

Thanks for your help.
It's on the front.
I can't seem to get Flickr photos posted, so check out the link. (I cleaned up the area hoping to get it welded.)
https://www.flickr.com/photos/83131266@N00/15837471501/

Here she is parked above the tree line, over 11,000' near Yosemite.
https://www.flickr.com/photos/83131266@N00/15653595100/
Yes, that is a glacier to the left. I watched a guy ski down it on that day, July 4, 2012.

I'll be gone on a back country vacation for the rest of the month, but I'd appreciate any ideas.
Thanks again guys.

 

[swshawaii]

Any way of getting a Tee Nut in there?

 

[Alluvialfan]

I'd need washers on that, and a way to stop it from turning. My frame isn't that thick, and I can't even touch the backside of these holes with my finger, let alone with a wrench. Someone suggested a rivnut type fastener, but they don't come close to 12 MM.

 

[swshawaii]

Rivnut is a great idea. M12 size is available, only problem is finding them sold individually and having the tool.

https://www.google.com/search?q=m12...a=X&ei=FuhuVO_jN8e7iQLqq4GwDQ&ved=0CAcQ_AUoAg