Stuck Cotter Pin

[Rubi04Jeep]

I am trying to replace the front track-bar on my 04 TJ. The passenger side came out without a problem, the issue is there is a liberal amount of rust that has built up on the driver side. The first issue I'm having is the cotter pin won't budge, is there any help for this, other then a liberal amount of PB blaster?

The other issue I am having is trying to determine what size this nut is? I've read a few write ups and most omit this detail.

Is there any way to tell that a track-bar needs to be replaced? During inspection I was told it needed to be, I'm just trying to estimate if it was the shop doing the inspection or is really needs to be replaced. Given the amount of rust, i'm not complaining, just wondering.

Thanks

[WILL]

The nut might have turned a little and is putting pressure on the pin. Use on open end wrench to turn the nut whichever way it needs to to relieve the pressure and it should come out. Might use something to tap the pin out after relieving the pressure also.

[bandhmo2]

What Will said. Also it often helps to use wire cutters to cut the ends off flush with the nut and they use a punch to drive it out. Trying to drive it out without cutting generally just leads to the cotter pin bending.

You should never reuse cotter pins to so there is no harm in destroying it. I have violated the never reuse rule but only on very none critical none vehicle type stuff. Reused cotter pins can and do fail so don't take chances on the Jeep.

[pontiac58]

The easiest way to get it out. Cut the pin off as close as possible. Then just us a socket on the nut. You may have to give the socket and few taps to get it by the cut pin. Then just loosen the nut. What is left of the pin will just shear off.

[jeepnut_nh]

if the wrench size is 9/16" then the nut is probably 3/8-24 castle nut

if the wrench size is 3/4" , the nut is probably 1/2-20 threads....

[Rubi04Jeep]

Thanks all for the reply. I'll give it a shot trying to jar it a little loose then cutting it down.

Thanks for the for the sizing, this will help as it's a tough area to reach.

[csc_wyo]

My old man and I fought this for about two days on an older truck of his. We were worried that cutting it off close and backing the nut off would damage the threads beyond the point of rethreading...especially in this hard-to-reach area. After so long, hours of cussing, he got quiet (which really just means super pissed), drug out the welding machine, bend a rod at a 90deg angle, properly aligned up to the looped end of the cotter pin, tacked the welding rod to the end of the pin, and then proceeded to yank the hell out of it until it was out.

In victory, a beer was drank with a chunk of cheese and some home made jerky in silence, and we continued to work on it. I haven't had to do this again, but when all else fails, think outside the box...and have a beer!

[peteyg]

The broken pin won't do anything to the threads. I don't even waste my time with stubborn cotter pins any more, and just run the nuts up breaking the pins. Never once have I had a problem with this method, and then I just get a new cotter pin and life is much happier.

[BUCKYOO7]

cut the pin and and put a socket on the nut and turn it loose if the stud turns put pressure on the track bar (upward)it is a tapered stud like a tie rod