Land Rover Defender: Steel Subframe Thread Repair Insert

GENERAL PROCEDURES

SPECIAL TOOL(S)

JLR-502-041

Steel Subframe Insert Kit

ACTIVATION

CAUTION: Make sure that the drill speed is not at maximum when repairing the damaged hole/thread. Use a suitable electric drill with a slow speed setting.

NOTES:

• This procedure contains some variation in the illustrations depending on the vehicle specification, but the essential information is always correct.
• This procedure contains illustrations showing certain components removed to provide extra clarity.

1.

CAUTION: Apply a suitable cutting lubricate to the drill bit prior to drilling.

Using the M12 drill bit supplied, drill out the remaining thread.

Special Tool(s): JLR-502-041

2.

NOTE: Apply a suitable cutting lubricate to the tap bit prior to re-threading.

Using the M12 cutting tool provided, install a new thread.

Special Tool(s): JLR-502-041

3.

WARNING: Eye protection must be worn.

Using compressed air make sure the hole is clean and free of debris.

4.

Using the special tool, install the insert.

Special Tool(s): JLR-502-041

5.

Make sure that the insert is correctly installed.

6.

Using the special punch tool, remove the remaining insertion tang shown above.

Special Tool(s): JLR-502-041

7.

CAUTION: Apply a suitable cutting lubricate to the drill bit prior to drilling.

Using the M8 drill bit supplied, drill out the remaining thread.

Special Tool(s): JLR-502-041

8.

NOTE: Apply a suitable cutting lubricate to the tap bit prior to re-threading.

Using the M8 cutting tool provided, install a new thread.

Special Tool(s): JLR-502-041

9.

WARNING: Eye protection must be worn.

Using compressed air make sure the hole is clean and free of debris.

10.

Using the special tool, install the insert.

Special Tool(s): JLR-502-041

11.

Make sure that the insert is correctly installed.

12.

Using the special punch tool, remove the remaining insertion tang shown above.

Special Tool(s): JLR-502-041

13.

CAUTION: Apply a suitable cutting lubricate to the drill bit prior to drilling.

Using the M10 drill bit supplied, drill out the remaining thread.

Special Tool(s): JLR-502-041

14.

NOTE: Apply a suitable cutting lubricate to the tap bit prior to re-threading.

Using the M10 cutting tool provided, install a new thread.

Special Tool(s): JLR-502-041

15.

WARNING: Eye protection must be worn.

Using compressed air make sure the hole is clean and free of debris.

16.

Using the special tool, install the insert.

Special Tool(s): JLR-502-041

17.

Make sure that the insert is correctly installed.

18.

Using the special punch tool, remove the remaining insertion tang shown above.

Special Tool(s): JLR-502-041

19.

CAUTION: Apply a suitable cutting lubricate to the drill bit prior to drilling.

Using the M8 drill bit supplied, drill out the remaining thread.

Special Tool(s): JLR-502-041

20.

NOTE: Apply a suitable cutting lubricate to the tap bit prior to re-threading.

Using the M8 cutting tool provided, install a new thread.

Special Tool(s): JLR-502-041

21.

WARNING: Eye protection must be worn.

Using compressed air make sure the hole is clean and free of debris.

22.

Using the special tool, install the insert.

Special Tool(s): JLR-502-041

23.

Make sure that the insert is correctly installed.

24.

Using the special punch tool, remove the remaining insertion tang shown above.

Special Tool(s): JLR-502-041

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