D.D. Machine doubler issue

[4x4junkie]

Anyone else with a 1350/1354 D.D. Machine kit having a hell of a time keeping the 'star' shaped ring piece that bolts to the face of their rear t-case from coming loose?

2nd time this has happened... I think it's because I can't get those flat-head hex bolts tight enough without turning my allen wrenches into little candy canes. Wondering who else has run into this and if you've figured out a fix? (thinking steel helicoils in the aluminum case along with Loctite is my best hope)


Anyone know if bolts like these exist in a Torx version?

Anyone got any other ideas?

 

[Sasquatch_Ryda]

You can usually grab an allen head bolt with a torx for better grab. Can't find a allen or torx socket to tighten them? I would locktight them in for sure.

 

[snoranger]

Tighten them down, take a center punch and peen the metal right next to the head in 2-3 spots around it. It wont back out on you, but you can still remove it later without needing a torch.

They do this from the factory on Taylor Forklift carriage and mast rollers. If those bolts back out, they can take out a $20,000 mast or even worse, kill someone. If it works on them, it should hold your doubler bolts in.

 

[4x4junkie]

Not sure I follow that, peen the aluminum next to the round bolt head? or ?

(remember, these are recessed bolts in an aluminum plate)


Sasquatch, I had thought of using a socket bit too, though stripping of the bolt head itself was my very next concern right behind destroying all my wrenches lol. I hadn't thought of trying an actual Torx in it though... Maybe I'll try that, see if it feels like it might work.

 

[snoranger]

Not sure I follow that, peen the aluminum next to the round bolt head?

(remember, these are recessed bolts in an aluminum plate)

Yes, peen the aluminum next to the the bolt head. It will put pressure on the bolt head and not allow it to turn as easy.

 

[sbsrlewis]

Now I'm curious...I'm going to go home n check mine to see if they they r lose. Better not be because we used loctite when assembled.


Steve

 

[4x4junkie]

You'll know if they come loose... All the fluid will start gushing out leaving the underside of your vehicle a big huge mess

 

[Hahnsb2]

Not sure I follow that, peen the aluminum next to the round bolt head? or ?

(remember, these are recessed bolts in an aluminum plate)

Basically like staking the gas key screws in an AR15 bolt.

 

[4x4junkie]

Hmmm... I would never have thought that would do anything against a round, hardened bolt head, especially with soft aluminum...
Good to know. (though on the AR it looks like it actually overlaps the head slightly, which I don't see occurring on my doubler plate)

I think I've already got another solution figured out for it though, just waiting on some parts.
Appreciate the responses.

Oh, BTW, the Torx in the hex was a no-go (too loose of a fit, and next size up was too big).

 

[4x4junkie]

Hoping this should keep it from loosening again...
I put longer bolts in and then put nuts on the backside in the 4 places I could. For the 5th one, I put the helicoil in hoping the steel thread will let it clamp down better (less friction during tightening).


I tried peening them as well, but there just wasn't much material around the bolt heads to get a real good bite on them, they're almost exactly flat with the face of the plates, so hopefully the nuts (Loctited on there) will do the trick.


Figured I'd also make it a little easier to get at that one small bolt inside there that's otherwise the biggest royal PITA.



Hopefully I can get this beast back in the truck by the weekend lol.

Thanks again guys