I was installing a used mopar hitch onto my liberty and using the bolts that came with the hitch. I used PB Blaster and a battery terminal brush to clean out the threaded holes on the Jeep. They were going in Really tight and I think I cross threaded them. One of the nutzert or whatever is the receiving thread broke off so now I have a hitch that is being loosely held on with 4 bolts (I hadn't gotten to the one under the exhaust yet) that are all half way in and REALLY tight and don't know how to fix this issue without digging a deeper hole for myself.

Thanks,
Craig

I would personally back the other bolts out and use a die/tap set to rethread the nutsertz. Then I would get new bolts. Is there an opening near the broken nutsertz that you can get a wrench through to hold it? I personally don't have a hitch so I'm not to familar with that area of the KJ. You can always use a cut off wheel, angle grinder, hack saw, etc. to cut the bolt. Unfortunately that won't fix the nutsertz problem, but at least you could move the hitch out of the way so you fix the nutsertz problem easier.

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07 KJ Sport 4x4, 3.7, 42RLE, Black, and mostly stock for now.
Westin Tail Light Guards and Gutter Guard Inserts.
Wish list is: Frankenlift II Premium, 245/75R16 tires, Al's UCA,
Skink Super Sliders, Full set of Skidplates, ARB Bumper, Warn 8000,
ARB lockers, and I'm sure that I'll come up with more...

If I understand your OP correctly you already broke one of the welded nuts that are inside the frame rail off ?? STOP !! get the remaining bolts out of there and go to the local hardware store and buy a metric tap 12 X 1.75 I believe the size was. If you keep trying to torque the bolts in you'll most likely break more. The tap is like $5 and wil clean and clear the threads MUCH better than trying it with a wire brush. I just followed the advice of other here and I'm glad I did after seeing the amount of rust and crap that the tap cleaned from the threads. The bolt by the exhaust is a PITA but if you use a ratchet strap you can hold it out of the way enough to get the tap up there and get it cleaned out.

New grade 10.9 metric bolts should run you somewhere in the range of $12-16 for all 6 of them from your local hardware store. I found it wasn't hard installing the bolts after using the tap to get everything cleaned out, hardest part was making sure I started the tap straight.

As far as the broken nut goes I don't know what to tell you, mine seem to have been welded inside the frame rails...........

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'02 Sport 4x4, 3.7L, 245/70R16 Bigfoot A/T tires, Tow Hooks, Rear Hitch

So the problem is mostly solved. Thanks for the help guys. I backed out the other 5 bolts and used a grinder to cut the bolt with the broken nut. I borrowed a tap and die set and tapped the 5 good nuts (holy moly there was a ton of crap in there). I also re threaded the 5 remaining bolts with the matching die. They all went in like butter after that. I went to a few auto parts stores and a fastenal and home depot and none them had nutzerts (all but fastenal had no idea what they were). I'll try to order one online i guess.

Question:
For those of you that have had the rear bumper off, would it be possible to get a new nut down the unibody frame rail and hold it with a long wrench to get that last one bolted (it's the mounting spot closest to the bumper anyway) if I took the bumper off?

Thanks,
Craig