I can't believe that bolt won't come out. If you have not yet stripped the bolt head, or broken a socket, you're not trying hard enough. Big breaker bar...several feet long...3/4 or 1" drive. Maybe you can rent one from AZ.

 

Yup, exactly what I was thinking. Thanks again, -Al

 

As a final update, I was finally able to install the leveling kit without removing the lower strut bolts - which had proven beyond a doubt they weren't coming out without drastic measures. Compressing the spring using spring compressors on both sides, prying the rubber damper loose from the top plate, then rotating the plate 180 to align with the new bolt pattern does work. It was a battle the entire way though - especially getting the now extended strut tucked back up in place and the studs lined up with their corresponding holes. Major patience (as well as pry bars/BFH ) required!! I would not recommended this plan without exhausting the possibilites of removing the lower bolt. It'a a good plan only if faced with the potential of replacing the strut or lower a-frame.
-Al

 

I've had both my lower bolts out for shock replacement reasons and they had no difficulty.

 

Rest assured if there were a remote possibility of those bolts being removed with no damage to the parts around them I'd have much rather gone that way.... I'm fairly handy and couldn't manage, so when the frame shop I took it to could do no better, I thought it beneficial to come up with a plan B.

I'm glad you had better luck. This note left for others that may not be so lucky.

 

Finally got time to install my level kit today (2" Daystar poly) ... 600ft lbs IR impact wrench AND heat to get the nut off. Funny part was it was torqued w/ a torque wrench (60 IIRC) to spec about 6 months ago. Rust was not a factor in this problem.. No stripped/crossed threads either.

Was sitting there thinking WTF and took about 30 minutes to finally get it loose. Once loose it came out fine, but damn.

 

<<<Was sitting there thinking WTF >>>

Holy cow....
Spent plenty of time with that same thought. This bolt did not look like it was going to be any kind of issue when I started on it. I mean, rust or whatever, didn't appear like it was going to be the factor it turned out to be. There's very little corrosion you wouldn't expect to see anywhere around it. It's like somebody covered the bolt with red loctite prior to inserting it!

Glad to hear you got'er done! I love the way mine looks and drives now. Worth the trouble? Yup, but I sure had my doubts at the time!!!

 

Put some pics up guys. We havnt seen either of your trucks yet.

 

Yes looks very nice now. No issues, at full droop I'm about 1/8" from the coils, but I don't take it anywhere that would cause anything even close to that so should be no problem. The nut I'm speaking of was on the driver side, and would NOT loosen, and I was doing my best to hold a tool on the head on the backside and it was wanting to twist my hand off. My hands are VERY sore today though.

One the nut finally came loose there was nothing that really should have interfered with the removal of it. After that the bolt itself just knocked through with a 3/8 ratchet extension and a hammer.

Kind of bothered I couldn't get a torque wrench on the top bolts (clearance issues with the wrench itself. Had to use a box wrench until I can figure something out. Pretty darned tight as they are though. I think the value on those top are 75 ft/lb.

Couple of months from now they have to come out for some new Rancho shocks, but taking a bit of a break on the mods for a bit.