Subframe - Repairing Damaged Threads

CATEGORY
Body

SECTION
8

PAGE
103

ISSUE
02/95-0553

CODE
810

Subject:
Repairing Damaged Threads in Subframe Mounting

Application:
1994-900

It is possible when removing and/or fitting the subframe for the threads holes in the body for the subframe mountings to become damaged. Should this occur, follow the direction below to rectify this. Helicoils listed below are equipped with special locking pins. Helicoils without locking pins must not be used.





Cars Affected:

Action:

If the welded nuts have become detached, but the bolt is in position, the head of the bolt must be cut off first. Then, weld the nuts in place as follows:

1. Disconnect the negative battery cable. If installed, remove the subframe.





2. Drill three holes in accordance with the measurements shown in the diagram, Figure 1.

3. Center the weld nut.

4. Plug weld the nut through the three holes in the body. Remove the bolt if it is still in the weld nut.

5. Go over the welds with a grinder and paint them, using appropriate primer.

6. Apply rust inhibitor around the welds and inside the subframe member.

7. Fit a new thread insert. See below.

Fitting new thread Insert:





1. Drill out the old thread. Use a drill with 16.5 mm on the front (Figure 2.A) and rear (Figure 2.0) attachments and a drill with 18.5 mm on the middle (Figure 2.8) attachment.

2. Tap the holes. Use tap with dimension 18 x 1.5 mm on the front (Figure 2.A) and rear (Figure 2.0) attachments and the 20 x 1.5 mm tap for the middle attachment.

3. Apply Loctite 242 to the thread insert and fit it in place.

4. Drive home the four locking pins.





IMPORTANT POINTS TO BEAR IN MIND WHEN FITTING THE SUB FRAME:

1. Using a service jack. raise the subframe until it is about 20 mm from the body.

CAUTION
Use new bolts (P/N 43 45 666) for the rear subframe mounting joints.

2. Do all six bolts up by hand, starting from the center.

3. Tighten the bolts.

CAUTION
Do not use an impact wrench or thread damage could result.

Warranty Information:

To resolve a customer complaint for a vehicle in warranty or if this occurs while performing PSI 02/95-0551, please submit a claim using the following information:

Failure code; 71100-78-0-01/06-05 (cannot be claimed in addition to 10816).

Labor operation: 71101 for 1.2 hr.

Straight time with helicoil: 0.6 per bolt.

Straight without helicoil: 0.2 per bolt.

Straight time for welding; 1.0 hr. for the first nut and 0.5 for each additional weld.

NOTE:
If you have to sublet the welding, you can add an additional 10%.

CAUTION:
When welding, disconnect the negative battery lead and cover it.