Energy Suspension body mount bushing replacement on 1st gen double cab

Not sure if this is a better picture but the more I look at it, I think the body would have to go up further not only to access th bolts, but to even get the bushing out.

 

The plate bolts are a PITA. They are all sorts of rusted. As a rust belt tech I have a set of 6 point box end wrenches for that kinda stuff. Another option is to get a dremel with a small cutoff wheel and cut the nut off or into pieces and chisel it until it comes out. You're don't look that bad some pb blaster a torch and a 6 point box end wrench and you'll get it.

 

Ok thanks. The nuts here are welded on. Would you still consider cutting them off, or should o go at the bolts from above and resort to the cutting as a last effort. I actually have brand new OEM frame perches for all six positions, but I am also in the middle of a house move, so I don’t want to replace ones I don’t have to at this point. I want to get this truck back on the road. I’ll eventually replace them , but right now, only the rear passenger perch was completely rusted through.

 

They are just spot welded on. It'd be a last resort but you can just knock them off if you hit them hard enough. I cut mine up and chiseled them off.

 

Ok. Thanks. Going to try and tackle them tomorrow. Also want to grind off remaining lip of the Position 3 perch and maybe even get new one welded on.

 

Ok. Got the middle one out and new one in today. That is not the correct long bolt, I just used it to center the washer when I lowered the truck. The passenger side ones are all out. Hopefully can get new body mount perch welded in tomorrow.

 

How did you end up getting the bolt to release from the bushing sleeve? I'm having the same problem on position 1 passenger side as well.

 

It was just sort of rusted in the sleeve. I used Kroil and a hammer and a block of wood eventually knocked it loosed. I didn’t have the same problem for the driver-side Position 1 bolt. That one came right out. I wound up cutting off the Position 3 perch on the driver side and welded a new one in. It wasn’t as rusted through as the passenger Position 3 perch, but it was getting there. The only one remaining for me is the driver side Position 2. The perch is in good shape but the bushing plate bolt heads are completely rusted. I am going to have to cut those welded nuts out. Here are my new perches.

 

Nice work on the new perches. My position 1 ones are slightly more bent than they should be, but I didn't realize parts were available to replace them.

For the position 2 mounts, I recall having to lift things worryingly high. Also, my sliders tilt slightly up, and were within an inch of the pinch weld normally, so the 2x4 may be giving more clearance than it appears from the photos. I used a combo of a jack as close to the mount as I could and a 2x4 lever near the mount to get the clearance initially, then would slide another 2x4 in to hold. Probably had to repeat 3-4 times before I finally had enough room. If you're braver than I was, probably can get it in 1-2 lifts.