Best way to remove a stuck nut

I'm doing a few jobs on the 90, all of them 1 or 2 spanner job according to the Haynes manual. However, as usual I'm stopped because I can't undo a bolt or a nut or a screw or something. I've got one at the end of the front shocks which is a pain, even with a good grip on the shock. I've also got 2 in a fiddly place holding the fuel tank on.

So I'm just wondering how people undo bolts and nuts that are rusted together after 30 years?

I've tried WD40, heat, violence, swearing and am now down to destructive means and am looking for people's advice. I'm thinking:
nut splitter - all the reviews are pretty poor, do they really work.
cutting - I can't get an angle grinder in there but I'm thinking of buying an oscillating saw.
other options - I'm all ears?

Many thanks,
Steve

It's hard to get damper nuts off I've found. If they don't come off and there is no access I just cut the damper away somehow and buy new ones as they are not exspensive really. A dremall type tool may be useful as is a lot of heat, a gas cannister type torch isn't always enough, I've got oxy acetalene for the tough ones.

if you have acess to gas heat nut until white hot then quelch it with water until quite cold or split nut with air chisel if nut ison something solid split with chisel and hamer

A small ratchet strap [ ratchet itself not needed ] wrapped around shock with hook on the spring strap will self tighten and hold shock to undo nut.

I have a set of chain vice grips (not sure what the correct name is) that I bought especially to undo shock nuts. Although as Flossie said I would not tend to cut and replace if it was that stubborn. Just remember to reassemble everything with lots of grease and copper grease so when you come to do the job again you won’t have the same problem.
For awkward bolts that are very stuck I tent to just keep turning until it shears and then replace. If it is rounded out that is a differant problem. And the angle grinder or dremel is called into action. I have in the past if very awkward resorted to a junior hacksaw blade on its own and a lot of patience.

The nuts are rounded and awkward to get to.
In general would a dremel be more use than one of those oscillating tools? I think I need to buy something to help cut the nut but can't work out which would be most use in general. Any thoughts?

steve2k said:

The nuts are rounded and awkward to get to.
In general would a dremel be more use than one of those oscillating tools? I think I need to buy something to help cut the nut but can't work out which would be most use in general. Any thoughts?

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Club hammer and sharp cold chisel is usually effective.

I don’t have an ocsilating saw. But I use the dremel fairly regularly. The flexible extension attachment is very useful as it makes it even smaller to get into the hard to reach places.

Oscilating tool will be good with the right tooling.
Nut splitters work, not the cheap ones but a decent make will do the job.
Where possible try and use stainless on the refit and some grease on the threads, makes life so easy the next time.

Good sharp chisel and club hammer if the oxy acetalene doesn't work.

sometimes on shocks good air wrench or battery powered impact gun will spin it off if as the shock cant keep up

or as Flossie posted, cut the strut and replace.

Cavey_P38 said:

Good sharp chisel and club hammer if the oxy acetalene doesn't work.

sometimes on shocks good air wrench or battery powered impact gun will spin it off if as the shock cant keep up

or as Flossie posted, cut the strut and replace.

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The front shock bottom nuts are a real fcuk womble, its even tight with a spanner and impossible with impact guns.

If you can get a drill at it, drill as big a hole as you can in the nut before using a chisel - it will split much easier.

If poss I find junior hacksaw/dremel cleaning the outer edge where nut meets surface can break the rust/bond.......sometimes......

Heat and swearing, chain clamp cold chisel etc all on call with Defender ownership, comes with the package.

Angle grinder often second choice tho..

Nut splitter I have works well - as said drill a hole first where you intend splitting.

Shocks - def agree that unless they are pretty new just cut out and replace the whole thing - amazing how much they 'go off' without you noticing, and new ones for reasonable price (reputable brand) make a real improvement anyway.... ;-) Cheers, A

Thanks all for the advice, i used a combination of all of those - from nut splitters, angle grinders, cold chisel, sodding big lump hammer. I've also bought new bits and SS nuts and bolts to replace them all with. Thanks again.

heat or induction kt

Impact wrench after soaking in penetrating oil. Switch back and forth on forward and reverse, for short bursts. oiling quite often.

No way of getting an air wrench on Defender front shock.