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.

• 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 

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 ground 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

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Loosening threaded mandrel

Fully riveted threaded bolt:

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Riveted threaded bolt