Broken motor mount bolts, HELP!

[redneck]

Since I bought the 95 Cherokee 3 weeks ago I have been tracking down a clunk that was in the front passenger side area. I thought it was the control arm bushings and I was planning to change those out. I also saw that it could be the sway bar bushings so today I went to Napa and got them. Well I got to find out what it really was today. I was ironically on the way back from Napa with my new bushings when this happened. As I went to pass some one making a right hand turn when it happened, POP! It was loud and had enough force that it knocked the pocket thermometer out of my vent. Scared the crap out of me. On the way home I noticed the temperature was higher than it usually is but I just passed it off as warmer weather. I popped the hood when I got home and noticed that the fan was not going; only the electric was. I shut her down and went to spin the fan. This is when I knew I had a problem. The bottom half of the fan shroud was missing and I noticed the motor was cocked funny. Motor mounts... I went back and got the mounts and I started on the drivers’ side. Piece of cake, done in 10 min. I started on the passenger side and immediately noticed something was not quite right. I then found something that I knew I was not going to be able to fix tonight. All three of the bolts that go into the motor have sheered off inside the block. F#^$!!!!! :flamemad: . I need help. This is my daily driver and I cannot afford to have it towed to the dealer or some shop for them to fix this. Have any of you dealt with this before? I feel rather confident mechanically being 17 years old but drilling into the block in that tight area is a little out of my comfort range.
Thank you for any and all help.
Aaron
http://rides.webshots.com/album/557089775GviDXi

[sjkimmel99]

Well, that sucks.
Here are a few threads about broken motor mount bolts:

http://www.naxja.org/forum/showthread.php?t=42516&highlight=broken+motor+mount+bolts
http://www.naxja.org/forum/showthread.php?t=46858&highlight=broken+motor+mount+bolts
http://www.naxja.org/forum/showthread.php?t=72062&highlight=broken+motor+mount+bolts
http://www.naxja.org/forum/showthread.php?t=19272&highlight=broken+motor+mount+bolts

Looks like people either drill through the fender well (hmm, just looke and that doesn't seem too easy) or with a 90* drill and use an easyout. Or add a blob of weld to the end of the bolt so you can get a grip on it with something (vise grips.) Also heard people suggest PB blaster or heating with a torch (clean the oil off) and touching a candle to the end of the bolt so the wax gets wicked into the threads to help loosen the bolt. Bolt tension is usually applied by the head of the bolt so unless they're corroded they should come out if you can get a grip on them one way or the other.

to make room, remove the battery & tray, undo the A/C compressor (the belt, 4 bolts and a wire) and pull it and the hoses over into where the battery was. maybe even undo the 1 bolt holding that other AC canister (evaporator?) next to the wheel well. Or try it from underneath.

[xjnco]

Happened to me also . You need to got the block up high enough to use an EZ-Out drill bit to drill the bolts out. The drill should 1/2 in. with reverse drive so it has some torque to it. You will first drill a small pilot hole then use the ZX out bit. Mine broke while on a trail and a buddy used three batteries & jumper cables and welded the motor mount itself to the block. This was very tricky with the two different types of metal. Lucky we had some welding rods! It held for 6 months or so, A cheap shop tried to weld the bolts to the mount after it came loose again and ruined the flux of the iron block, so don't try that, or you'll have to get a replacement motor. Good luck, Mike

[xjnco]

Sorry, I'm talking before thinking! For sure, the way to get the bolts out is to use an EZ Out. Removal of the hood first will make it easier. use an engine hoist to raise the motor. Before you to raise the motor you will need to disconnect the transmission mount, the other motor mount and pull the driveshaft. When the motor is raised so you can get at the bolts, you will need to drill a pilot hole in the flush bolt shafts for the EZ Out bit to fit in the hole securely, and then you reverse turn the bolt out with a wrench .

[redneck]

Ok, Ive went and got the EZ out thing but I havent been able to try it because i have broken 3 bits trying to drill out one of the dang bolts :smsoap: . Are there any bits out there that are strong enough to drill into a grade 8 bolt with out dulling and or braking?
Thanks
Aaron

[XJ20]

A cobalt drill bit would work better and will have different grind geometry and a 135° included angle for the drill point but you don’t need it if you have a bench grinder.

Different grades of materials require at times a modification of the commercial high speed steel 118° drill point for maximum results. Hard materials require a blunter point. That’s where the 135° angle comes into play. You can also give the lip more clearance and a flatter rake or chamfer. Some people call this a crankshaft grind. I do it by hand and have removed lots of grade 8 bolts from our cryo science grade instruments. It’s real easy to do but hard for me to explain. I think I could post a pic when I get home of the point.

Let me know if you have a grinder and I can post a pic that may help.http://www.dakotacom.net/~jeepster/tipshades.gif

[redneck]

XJ20, I have a grinder. Ill try anything at this point to get it done. Ive been getting quotes from shops to fix this and it will be $200-$300 for them to fix it without removing the motor and $900-$1200 if they need to take the motor out. On top of this the dealership was the first ones able to get me in and thats tuesday of next week if i cant do it myself.

[XJ20]

How far do you live from gilbert? I’ll be picking up an axle early tomorrow morning there, pm me your 20.

I could explain later in a pm about drilling that pilot hole, too. http://www.dakotacom.net/~jeepster/tipshades.gif

[redneck]

XJ20, I went out and got a few of thoses colbalt bits. Its nice when you have the right tools. Thanks for steering me in the right direction. I was then able to get two of them out but i cannot get the last one. I used the two diffrent size bits and three diffrent sized extractors but they will not catch anything. Where do I go from here?

[XJ20]

Work on that third one until it backs out, lol. http://www.dakotacom.net/~jeepster/tipshades.gif

edit:
modify the length of your extractor to get a good grip on things.http://www.dakotacom.net/~jeepster/tipshades.gif

[xjnco]

Sounds like things are working out ! :yelclap:
Good deal.

[rockwerks]

try jacking up the motor several inches to get a better angle on the last one

[redneck]

Well I know this was not wise but I couldnt get the third one out and I broke a bit inside the hole. I ended up putting it back on with only the two bolts holding it on because I needed the jeep for a run up to Heber today. They stayed tight and are holding. Hold long can I run it like this until i can get it in for someone to do the last one? This is my daily driver so it needs to be on the road.

[azdesertrhino]

Well I know this was not wise but I couldnt get the third one out and I broke a bit inside the hole. I ended up putting it back on with only the two bolts holding it on because I needed the jeep for a run up to Heber today. They stayed tight and are holding. Hold long can I run it like this until i can get it in for someone to do the last one? This is my daily driver so it needs to be on the road.

I think the longevity will depend on the stress put on them. I would make it a priority to get the situation resolved as soon as possible. Wish you were closer, we would gang up on it and get it resolved.

[rockwerks]

I think the longevity will depend on the stress put on them. I would make it a priority to get the situation resolved as soon as possible. Wish you were closer, we would gang up on it and get it resolved.

I dont think Ive ever heard of the pre 91 XJ's having the issue, both my 95 and 96 have but none of the 87,88,89 or 90 did..........

Just in case though IM going to weld that plate to the block, tack it in about 4 places

[xjnco]

Or you could drill the holes out a little and put Heli-Coils in for a larger(stronger) bolt. Also use a grade 5 or better bolt, prefer a grade 8, but they are harder to find.

"and if you keep the bolts tight, they won't break" :huh:

[redneck]

I have two grade 8 bolts in there right now and they are tight. I've never had a problem finding grade 8 bolts, Ace has always had a nice selection. Thanks for all the help.
Aaron