Track Bar Bushing vs Bolts - : Jeep Wrangler JK Forum
View Poll Results: Which Solution?
Solution #1 w/Bacon 0 0%
Solution #2 w/Bacon 3 100.00%
Solution #3 w/Bacon 0 0%
Solution #4 w/Bacon 0 0%
Voters: 3. You may not vote on this poll

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post #1 of 2 Old 01-04-2012, 11:55 AM Thread Starter
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Track Bar Bushing vs Bolts

I'm pretty sure I have the why figured out but what to do is still open.

As mentioned in previous threads, Chrysler used slightly smaller bolts than the proper 9/16" required to hold the track bar in place. This appears to be causing premature bushing failure. As best as I can tell as to why they did this is because there is no such thing as a 9/16" flange bolt on the market. There are hex cap bolts but not flange bolts. One nice thing about the hex cap bolts is they can be purchased with only partial threads to provide a larger contact surface.

After some research I have come up with only 4 possible solutions:

1) Custom made flange bolts and nuts. This is just not a realistic solution. The price tag for 2 bolts and 2 nuts (all Grade 8) is $700-800.

2) Purchase 9/16"x3-1/2" - 18 Grade 8 hex cap bolts and matching nuts. The remaining question here is whether or not to use matching SAE (tighter tolerance than USS) flat washers (x4) and split lock washers (x2) and/or use Loctite 271 (red). This is the least expensive and most readily available solution.

3) Purchase 5/8" bolts and have them machined down to 9/16". I don't know the cost of this and it still leaves the same issue of washers and nuts solution #2 has.

4) Replace the bushing and/or bore out the existing bushing and mounting holes.

After typing the above I decided to turn this into a poll. So what are the thoughts you might have? Perhaps a manufacturer or two could comment on solution #4?

Originally Posted by StubEXrube View Post
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post #2 of 2 Old 01-04-2012, 12:12 PM
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IMO, you are over-complicating it.

The factory bolt is actually working just fine for MANY JKs on the road. Upgrading it to prevent problems is not a bad idea, not necessary, but will not hurt.

I have upgraded to the standard 9/16"-28 grade 8 hardware, with hardened washers with plain-jane lock washers on mine. I have no issues, no loctite, no magic nuts, it works for me just fine.

...Therefore I vote for #2

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