I use a cutting torch to remove the bolts from inside the mounts. The
next best thing is a sawzall to cut the bolts and bushings inside the
mount and repalce all. Make the new bolts and nuts are at least grade
10.9, (I like 12.9) and use never sieze inside the bushing. Lock tite on
the threads or an all steel prevailang torque lock nut is also a good
idea.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Ed Carroll
Sent: Sunday, October 20, 2002 8:51 PM
To: vanagon@GERRY.VANAGON.COM
Subject: stuck shock bolts

I'm hoping someone can offer suggestions on my latest driveway
difficulty.

I'm putting on reconditioned brake calipers and cleaned up rotors, so I
decided that while I was in there I would put new KYB shocks up front.
The upper mounting nut on the first shock was a frustration, but with
days of penetrating oil, judicious mangling by Vice-Grips and finally a
nut splitter, off she came. The other upper nut came off easier.

The real problem is with the lower shock bolts. Nuts come off easily
enough, but then the bolt itself is thoroughly fused and become one with
the inner sleeve in the lower bracket tube (collet?) of the shock. The
first took more than four hours of hammering, heating, cheater bars,
etc.; the bolt/bracket sleeve combo spun loose from the shock's rubber
bushing, but then could not be forced out through the mounting hole. I
can't find a good spot to mount a puller or press. I'd like to skip the
burning bushing fumes, slashing about with a utility knife and pounding
and skinned knuckles with the second one, if anyone has ideas.

Ed Carroll
87 Weekender