Replacing Coarse Threaded Bolts

NOTIFICATION 

Drilling work not performed correctly 

• Risk of damage to components 
• Leaks 
  • Protect the component using a wooden support.
  • Use a bit stop while drilling.

Information 

The following bolts are available:

• Defective or broken coarse threaded bolts can be replaced with repair bolts. 
• Coarse threaded bolt, T5:  > BOLT 999.190.342.01 
• Coarse threaded bolt, T6:  > BOLT 999.190.501.01 

Information 

Check that there is adequate clearance at the back of the installation area. The bit stop must be used on the complete vehicle.

1. Grip defective coarse threaded bolts on the complete vehicle (e.g. bolts with damaged threads) using a pliers and screw them out.

   Grind down during body repairs if necessary.

2. Secure the bit stop.
   1. 2.1  Secure a setting collar on the drill bits used in order to limit the drilling depth. > Length 3.0 mm  > 9399/4 - Set of setting collars. 
3. Remove underbody protection close to the sealing surface of the repair bolt.
4. Drill a hole.
   1. 4.1  Drill a hole at the correct installation position. > Diameter 4.0 mm 
   2. 4.2  Drill out the hole.

      For coarse threaded bolts, T5 > Diameter 7, 0 mm 

      For coarse threaded bolts, T6 > Diameter 9.0 mm 

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      Drilling hole

5. Set up tool.
   1. 5.1  Pull cap -2-  off the riveting tool -1-  > 9399/1 - Riveting tool for around pins 

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      Removing cap

   2. 5.2  Attach mounting -3-  .

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      Attaching mounting

   3. 5.3  Screw on threaded mandrel -4-  > 9399/2 - Threaded mandrel + mouth piece 

      Left thread

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      Screwing on threaded mandrel

   4. 5.4  Attach mouth piece -5-  , -arrow A-  > 9399/2 - Threaded mandrel + mouth piece 

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      Attaching mouth piece

   5. 5.5  Screw threaded bolt -6-  in fully.

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      Screwing in threaded bolt

6. Rivet in threaded bolt.
   1. 6.1  Insert threaded bolt into the bore.
   2. 6.2  Rivet in threaded bolt using the riveting tool -1-  (pumping action) -arrow A-  . -arrow B-. 

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      Riveting in threaded bolt

7. Complete the riveting process.
   1. 7.1  When the riveting process is complete, relieve the hydraulics using the bleeder valve -arrow B-  . Continue to apply pressure to the riveting tool while doing this, -arrow A- 

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      Bleeding riveting tool

   2. 7.2  Turn the mounting -3-  to the left to release the riveted threaded bolt from the riveting tool -1-  .

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      Loosening threaded mandrel

      Fully riveted threaded bolt:

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      Riveted threaded bolt