Replacing Dilavar Studs In Crankcase

REPLACING DILAVAR STUDS IN CRANKCASE

Replacing Studs Which Are Broken Off Above Thread Runout on Crankcase End.

Tools



1 - Drill (special alloy) DBF - 1/4"
2 - Stud remover E - 3

1. Level off broken stud and punch mark the center point.




2. Drill an approx. 15 mm deep hole in stud with a 1/4" (6.35 mm) dia. special drill or hard metal drill of same size in a table or stand drilling machine.
3. Drive in remover approx. 10 mm deep with a hammer.
4. Heat crankcase section to about 200 °C / 395 °F with a hot air blower, e.g. VAG Special Tool 1416, or in an oven, in area of studs (to melt Loctite cement).




5. Unscrew remover including broken stud and hexagon nut.
6. Tap threads and screw in new Dilavar stud with Loctite No.270.


Replacing Whole Dilavar Studs




1. A stud remover from Rothenberger, designated Romax - Size 10, is suitable for removing whole studs.
2. A stud remover of the same make, designated Romax - Size 8, is suitable for unscrewing broken off studs with a protruding stud length of at least 30 mm.

Note: Heating the Loctite cement in the crankcase before unscrewing studs is important.