Captured nut replacement 101......

When I went to replace the leaf spring bushings on my 96, I found the shackles were shot. Decided I had to replace them, and that's where it got fun.

http://www.naxja.org/forum/showthread.php?t=1123285


So, fearing I had too little of the 'nut hump' left that was solid, and not wanting to really use the shackle relocation kits at this time (still deciding on the lift kit I am going to go with), I decided on a different route.

Basically, I made some replacement plates that will fit over the nut hump area, and had some 5/8 thick steel chunks, so I made new nuts from those.

Here's what I started with....yes, it ain't pretty, but I was trying to freehand with the plasma in an area I had a hard time reaching due to the way the jeep was supported.

And I ain't no good picture taker, so they are slightly blurred, but I think ya get the idea.

Drivers side


Passengers side


After the measuring & test fitting (found out the nut hump is not vertical....it has a 1.5 deg lean in at the top), here's what I got now
These slide up into the 'box' and will be welded in place with the square chunk towards the shackles & the angled edges up, and the old nut inside the frame
The square chunk is welded at a 1.5 deg angle in relation to the plate, and this gives me ~ .030" clearance when the shackle is installed.








Still need to dress them up & make them pretty, as these were taken right after welding them up, but I will update this once they are welded in place on the jeep..................

Right now, I am not sure if I will be able to weld the top edge in, or if I will have to do rosette welds.....not much room for the mig gun in that box

Well, they are in now,and seem to be working fine.



The back side weld looks like crap cuz I couldn't get the gun in close enough...and since I couldn't get to the top edge, I drilled a 1/2" hole just above & forward of the top corner of the 5/8" plate and did a rosette weld.

May not be as pretty as some, but I don't think it is coming out.

Good solution and I don't see that breaking lose like the factory bolts.

Thanks...ha...like your location....I been saying that since I got to VA in '86.

I did use a liberal coating of anti-sieze on all the bolts & inside the sleeves in the bushings so hopefully I won't have the same issues next time I have to take the springs & shackles out.

The front eye bolt nut is still stock, so we'll see.




In hindsight tho, I think I should have put the 'chunk' forward in the pocket instead of to the back like stock....would have also served as a shackle angle fix as well as the needed repairs.
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Out of curiosity, do you think this would work with the front hanger as well?

91to99 said:

Out of curiosity, do you think this would work with the front hanger as well?

Click to expand...

I don't see any reason it wouldn't.

thats a sexy repair.

TRCM said:

In hindsight tho, I think I should have put the 'chunk' forward in the pocket instead of to the back like stock....would have also served as a shackle angle fix as well as the needed repairs.
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Click to expand...

x2. I'm getting ready to tackle this dreaded area as well. A buddy of mine did this on his 87 and it worked great. Moved forward a bit and put the shackle at nearly a 45* angle and it was like night and day. Looks good though, nice work.