Well I decided to dig into my '87 xj starting with the front left brakes and such. I had been pb blastering the you know what out of the suspension parts for days now so mostly everything came loose EXCEPT the bottom caliper bolt. Heat, nope, more heat, nope, more heat plus a cheater pipe and snap the bolt head comes off. So now I remove all the parts that I could including the outer half of the caliper itself. I'm greatful for the clamshell design because it afforded me a straight path to cut the lower "ear" of the inner caliper half off:



this, in-turn, allowed me to cut the bolt off where the caliper body meets the lower tie rod bracket. Now I was able to back out the threaded remains of the bolt from the caliper body using vise grips. Finally with lots of heat, a bench vice, a heavy hammer and a punch, I was able to wack out the remains of the bolt shaft that had been rust welded into the lower tie rod bracket. This was the source of all my trouble. No anti-rust coating put on the bolt 25 years ago when it was probably last removed created this mess. The snapping of this bottom bolt must be common as the Welch salesperson said they hardly ever sell the top caliper bolt.



Before I start re-assembly, I have to twice coat the brand new calipers with rust preventative por 15 then apply many coats of black paint. I just hope the passenger side goes a little easier.

Question for the peanut gallery, was the old bearing seal pressed in? To remove it, do I just use a little gentle hammer persuasion? Both bearings are in good nick and came out easily (they are being replaced). The hub cavity was filled about 20% with old gunky grease.

More updates to come.

 

Wow, that bolt had really found a home! Most any parts house will have a seal puller, similar to the one in pic. Simple and quick. New seal goes back with some finesse. Make sure the seal is square to the hole, I use a large (3/4" drive) socket or a flat piece of hard wood/steel to hammer against. Once you get it started all around, you won't have any trouble-just keep it going in square and don't use a small ended punch, etc. you will dent the seal and probably ruin it.

Dave

 

Thanks Dave. Can't wait for my $10 bolt to come. I suspect there will be many more $$$$$ surprises as I dig into this car. It's a shame how often simple maintenance is neglected by past owners. I mean you can't have a wheel bearing hub lubed? Today I will probably be cleaning the original grease that is caked in the hub. Ren

 

don't waste money on por 15. might as well use Rust Oleum black paint. Ask me how I know. Blast the part then paint it.

 

Jose: hmmm. I've been successfully using por 15 for years with rusty, old calipers and brackets that I salvaged from junkyards. I will be giving por 15 a huge head start since I bought new calipers. Truth is this car will eventually be sitting in a scrap yard (not for many years though hopefully) and the calipers will look great with the rust protection they are getting.

 

You have No idea!!!

We all Love rebuild threads.
If we've been there, we nod and say, 'yup!'
If we haven't been there (yet) our eyes get big and we take notes.
(';')

 

Today's update: beginning to re-assemble front driver's wheel stuff. My car gave me a gift today, the right side lower caliper bolt loosened in the normal fashion.....yeah....

 

DON'T BE FOOLED!!
IT'S A TRAP TO LULL YOU INTO A FALSE SENSE OF SECURITY AND KEEP YOU OFF GUARD!

Congrats!
(';')