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Leaf spring hanger bolt stuck!

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Hey guys, I am currently in the process of replacing the rear leaf spring shackles and hangers along with swapping in some Explorer leaf springs on my 1990 Ford Bronco II. The front shackles look like they are in good shape so I am not going to replace them. I got the nut off of one side but the bolt is stuck inside the bushing. There is no room to get an air hammer behind the bolt. On the other side, the bolt broke off half-way inside the leaf spring. I am stuck and I don't know what to do to get those bolts out. Help!
 


86 slo-vo

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cutting wheel is your best friend...
 

BeaterMan

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Yea i've come across this more times then i'd like to remember. Like 86 slo-vo said a cutting wheel. You got to cut the bolt between the shackle/hanger and the leaf spring itself. Ive also used a sawzall. When you put new bolts in use antiseize- and i actually see a company sells a leaf bolt kit now i'll try and find where i seen it.
 

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and once you cut it out...chances are youll need a torch or some other form of heat to pound it out...i would bet you wont get it out of the sleeve, and will be better off burning out the old bushing and putting a new one in.
 

Yellowsplash

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If you can get the back nut off, you can spin the bolt in the bushing with an impact till it heats up and use something to try and pry while your spinning it to slowely work it out. Be sure to soak it all down real good with pb blaster. I just delt with this the other day...

I have a body lift so I could fit an impact in there, without one you might not.

As far as the broken one, cutting is the only way.
 
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pillen140

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cut the bolt between the hanger and spring on both sides.... press or hammer out the whole sleeve (and broken bolt) out of the bushing. the sleeve is split and will come right off of the broken bolt. reinsert with some silicone spray.... like magic.
 

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Hey guys, I am currently in the process of replacing the rear leaf spring shackle hanger and hangers along with swapping in some Explorer leaf springs on my 1990 Ford Bronco II. The front shackles look like they are in good shape so I am not going to replace them. I got the nut off of one side but the bolt is stuck inside the bushing. There is no room to get an air hammer behind the bolt. On the other side, the bolt broke off half-way inside the leaf spring. I am stuck and I don't know what to do to get those bolts out. Help!
Here are the process on how you can replace it...

  • Make sure the vehicle is parked on a solid, level surface to ensure that it does not roll or lean when raised.
  • Using a floor jack, lift up the rear of the vehicle enough for the axle assembly to hang freely.
  • Secure the vehicle with jack stands on both sides for safety before starting any work. Do not rely on the jack to hold the vehicle up while working.
  • Support the rear axle assembly with a floor jack close to the spring .
  • Remove the lower bolt from the shock absorber.
  • Lower the axle to relieve tension on the spring. Remove the U-bolts and spring retainer bracket.
  • If necessary, remove the parking brake cable from the retainer bracket.
  • 8
  • For springs that are mounted on top of the axle, carefully lower the rear axle. Do not allow the axle to hang from any hoses or cables.
  • Loosen the rear shackle bolts. Support the leaf spring with a jack stand. Remove the leaf spring front and rear eye bolts.
  • Remove the leaf spring from the vehicle.
  • Place the front bushing of the new spring into the front mounting bracket. Install the front eye bolt and nut. Make sure the bolt head is toward the center of the vehicle.
  • Place the rear bushing of the new spring into the rear shackle. Loosely install the rear eye bolt and nut.
  • Raise or lower the axle to place the leaf spring center bolt into the hole on the axle pad.
  • Install the U-bolts and retainer bracket. Snug the U-bolt nuts down but do not tighten. If necessary, reattach the parking brake cable. Attach the lower shock mount to the axle bracket.
 

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Gwaii suggested this and I had some success;
Cut the head of the bolt off.
Use some anti-seize on the threads.
Make sure the nut is fully threaded on or you will pull the threads off the bolt or nut.
Add some washers behind the nut and tighten.
Add more washers as needed.
Eventually you'll pull the bolt through.
Good luck,

Richard
 

chrwilkins30

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I actually just got done on saturday doing the exact same thing.
Make sure you have before you start
*Can of antiseize.
*9/16x5 grade 8 bolts(2),nuts(2),and washers.(4)
*I think 1/2x1 1/2 in grade 8bolt and nut.(2) for the leaf spring bolt swap.
*good cut off wheels.
*a crowfoot to get the front hanger nut from behind.
*New u-bolts in 2 7/8

What i did is take the bolt that came with the shackle that would go in the leafs and put it in the front hanger since i could not get the exact size I wanted. The bolt in the leafs needs to be turns otherwise cut it off. Put the 1/2 in. I had to round the head off a little to fit in the axle perch. and drill out the plate that hold the leafs spring to the axle. Also you will possible need to get new u-bolts. All mine broke. Just give your self a weekend. Also bp blaster will be your best friend.

Good Luck
 
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