hosehoundfr86

I have a 96 XLT and have to service the rear suspension but the front mag side axle bolt is seized in the shaft,, any hints or tips would be greatly appreciated

indytriumph600

Go in from the nut side after you take the suspension out and use a hammer and punch and best it out and if it has a grease fitting it wouldn't hurt to give her a squirt or 2

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BC_Dan

Not sure which bolt you are referring to...

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kccats

If the bolt is on a cross shaft, put the other side back in and tight, then use an air or electric Impact to breack it loose! If it snaps off, get the suspension out and then take the shaft out and clean up the end with the broken bolt. Weld a flat washer (not a nut) to the broken bolt! Let it cool a few min then turn it out with vise grips!

hosehoundfr86

it's the main front axle shaft bolt,, it's been well greased,, and the bolt on the left side won't tighten enough to get the right side to turn,,,I only worked at it for an hour or so,,and I may need an extra set of hands to hold wrenches,,,if the head broke off it would help and I may have to take my recip saw and cut the head off to get it out,,I have considered drilling a hole through the housing and putting a pin through to hold the shaft ,, I could then re-weld them,, any other thoughts are very welcome

Phaze

So the left side wont tighten properly? Can you get a tap in there to clean up the threads on the shaft? Then do what KC mentioned, use an impact on the right side.... A steady push on a wrench wont break it free. You need to jar it with an impact.

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hosehoundfr86

not sure the left side won't tighten "properly",both sides have grease on them,,,, it may have picked up some when it came loose, ,,cleaning the threads would probably help, I'll try that if I have a tap that large,,I was also thinking I might be able to pry the shaft assembly far enough from the tunnel to push a lock washer up between the shaft and the tunnel , then put the bolt back in and tighten it up,, then maybe the right side will come loose ,, I was also using 3/8 "extensions on my impact, I picked up a 1/2 drive swivel so I can use the bigger extensions and sockets,,, gonna try it again tomorrow afternoon,,,our snow just arrived ,, be nice to have it this week,,,,

hosehoundfr86

Got it out this afternoon,, did what I was thinking would work,, removed the left bolt,,,, pry d the shaft and housing out from the tunnel ,,put in lock washer on the end of the shaft ,,inserted bolt with another lock washer on it ,,, tightened it in ,,, turned out the other side,,I did spray wd40 in the bolt hole and blow it out with air and cleaned the threads on the wire wheel,,, I found the rear axle shaft worn so bad the track idler wheels were wobbling,,,I thought it was bearing's,, going to have a friend look at it tomorrow to see if it can be built up with his tig welder to save buying one,,, happy trails,,,,