Member Since: 08 Sep 2020
Location: Buckley, North Wales
Posts: 1150
I was going to say just now, I’ve removed the old ceased tow bar and noticed the bolts are in the chassis! But they are rusty and I can’t get them off so far!
Does anyone have any tips to salvage them please?Disco 3 SE Manual 2005 V6 2.7
Buckley, North Wales
26th Apr 2021 6:23 pm
Dave Shirley
Member Since: 22 Sep 2011
Location: Oxfordshire
Posts: 448
As I said before you will have to remove the swinging weight brackets to remove them from your D3, not so the D4.
If you are just replacing your seized tow bar, leave them where they are and just reuse them so you really don't need replacement bolts at this stage.
26th Apr 2021 7:10 pm
General_Git
Member Since: 20 Jun 2019
Location: Reading
Posts: 110
Fresh memories from a particularly protracted battle with mine. Were I doing another I would:
Firstly, the OEM bolts may fit without any hassle, in which case, ignore everything below and enjoy a 20 minute job...
Spray penetrating oil as much as possible on the bolt assembly on the outside of the chassis.
Unbolt Disco Balls so they swing. One bolt both sides.
Use a deep strong 3/8" drive socket to grip the (think it's 9 mm and a 1/4" drive is unable to handle the torque) smaller external longer bolt on the outside of the chassis and use a 21 mm spanner to release the nut. This will loosen the chassis internal thread that your tow bar bolt will mate too. I used this job as an opportunity to expand my toolset: deep socket set and 21 mm spanner.
If you decide to renew this internal bolt assembly (I had to as I rounded the 9 mm) DO NOT drop it in the chassis when you remove it or insert a new one or you will need to remove the bumper and drill a hole in the rear of the chassis just to see it inside. I then modified a coat hangar and there is just space to tease the little out through a small hole somewhere. Much quicker not to do that.
Also, I fought with the Disco balls as they are really in the way and I couldn't figure out their removal. In the end, I used an axle stand to support the thing away from my work but it was a continually frustrating conversation.
The reason you need the correct bolt is that the thread pitch is 2 mm on standard M14 bolts you can buy on ebay. I think (happy to be corrected) that the OEM bolt is 1.5 mm pitch.
Then, you are ready to fit. Tighten the internal tow bar mounting point while gripping the 9 mm on the outside. Finally, tighten the 21 mm nut on the outside and you're done.
Peeps have said that this is a 20 minute job, peeps also say that every 20 minute job is one bolt away from becoming a three day ordeal. Let us know how you get on.
The following diagram may help.
KVY500031 is both the insert and the 9 mm.
FY114056 is the 21 mm nut which again, I replaced on both sides.
I'm sure you can spot those pesky disco balls.LR3 MY05 TDV6 2.7 HSE - 130k
Audi S3 Black Edition Quattro (2020) - 11k
ZZR1400 (2010) - 55k
27th Apr 2021 9:20 am
DSL Keeper of the wheelie bin
Member Since: 11 May 2006
Location: Off again! :-)
Posts: 72779
Bit higher res, save peeps squinting.
Click image to enlarge
27th Apr 2021 9:31 am
Dave Shirley
Member Since: 22 Sep 2011
Location: Oxfordshire
Posts: 448
Just to add to the diagram kindly provided by General_Git and DSL, the part numbers of the bolts we are
talking about to secure the tow bar to the chassis are; FT114356P, KVY500031 and FY114056 so you can
see how the the bolts are made up.
Hope this all helps in curing your tow bar problem, I presume you are going to un seize and refit it?
27th Apr 2021 9:54 am
cmb2020
Member Since: 08 Sep 2020
Location: Buckley, North Wales
Posts: 1150
Unfortunately this makes no sense to me as the bolt is a weird design
So the outside nut holds the sleeve inside? Or I remove the outer nut, then the hex end would unscrew the bolt through the sleeve which is threaded?
Any videos?
The D3 balls?
Presuming the swinging things but how do I undo ?Disco 3 SE Manual 2005 V6 2.7
Buckley, North Wales
27th Apr 2021 11:03 am
General_Git
Member Since: 20 Jun 2019
Location: Reading
Posts: 110
I was exactly in your position when I started and like all these things, by the time you have completed the job you have completed your understanding. Start my spraying penetrant and investigating on your own vehicle.
KVY500031 is the key, inside the chassis it is the socket into which the FT114356P M14 tow bar bolt fits. Protruding through the outside hole in the chassis is the end of this part which has an M16 thread for the FY114056 nut and a 9 mm long hex end so you can tighten FT114356P before tightening FY114056 to complete the job. That is to say, firstly you anchor the tow bar bolt to KVY500031 then you anchor the whole assembly to the chassis with FY114056.
Removal of KVY500031 is achieved through gripping it on the 9 mm end (3/8" drive remember) and undoing FY114056. You are therefore working on the same side (outside) for both wrenching operations. Finally, swinging the disco balls out the way reveals a hole, can't recall inside or outside - I'll go for outside, through which KVY500031 can be completely removed. (Don't drop it inside). Expect this job to be a pain due to corrosion and the 9 mm end rounding off easily. I had rounded off my 9 mm end so much so that I ended up angle grinding the whole sorry mess off. Again, try not to get there.
In those immortal words, refit is the reverse of removal.. 8) but with added copper grease and of course you end up with a tow bar!LR3 MY05 TDV6 2.7 HSE - 130k
Audi S3 Black Edition Quattro (2020) - 11k
ZZR1400 (2010) - 55k
27th Apr 2021 11:19 am
General_Git
Member Since: 20 Jun 2019
Location: Reading
Posts: 110
Oh and for releasing the Disco Balls, you'll need to detach both KYG500250s and FY110057. I remember now, you will struggle to expose the chassis hole and move them to allow working room. Hope you have axle stands, bungees or perhaps cable ties to help.
I had to really bend the plate out the way with a big crowbar and rely on the clamping force provided by the nut on completion of the job to straighten it back again just to allow sufficient space to access the removal hole. I was worried I would deform it but I didn't in the end. Actually, this interference is the main reason I dropped the bloody new one in the chassis. This plate is helpfully un-numbered in the diagram but nuts 114056 and 110057 fit against it.
Someone here suggested removing these things (not forever, they do have a purpose) so perhaps someone else could oblige. It really would make the job simpler.LR3 MY05 TDV6 2.7 HSE - 130k
Audi S3 Black Edition Quattro (2020) - 11k
ZZR1400 (2010) - 55k
27th Apr 2021 11:27 am
cmb2020
Member Since: 08 Sep 2020
Location: Buckley, North Wales
Posts: 1150
Thanks I’ll try again today
You did this without removing the swing bracket?
So the outside nut comes off
Then hold the thin hex and undo the inter nut
Hold the hex bit which is part of the sleeve? Then don’t let the mole grips undo and it drop in?
Struggling to understand ideally need a vide for all on YouTube of itDisco 3 SE Manual 2005 V6 2.7
Buckley, North Wales
27th Apr 2021 11:52 am
cmb2020
Member Since: 08 Sep 2020
Location: Buckley, North Wales
Posts: 1150
I might just pay the local mechanic to do this oneDisco 3 SE Manual 2005 V6 2.7
Buckley, North Wales
27th Apr 2021 12:01 pm
General_Git
Member Since: 20 Jun 2019
Location: Reading
Posts: 110
I think i got the bracket off on one side but not the other, perhaps I ran out of patience at this point.
Yes, outside nut first but gripping the 9 mm end of KVY500031 (let's just call it the insert) is a tall order for some mole grips as I discovered to the cost of my angle grinder. Buy a deep 9 mm 3/8" socket. You then of course, cannot use a 21 mm socket hence the need for a spanner. Again, no faith in adjustables here. I bought a Halfords Advanced for £8.
I always think if you buy the right tools then you can only blame yourself when it goes wrong...
Once the nut is off the insert will be loose but you'll need to uncover the hole to remove it. It can't fall until you are trying to remove it through the hole so don't worry about it falling until you are physically trying to take it out.
Never found a video and ironically, once I had completed the job i wondered what all the fuss was about...well...nearly anyway!LR3 MY05 TDV6 2.7 HSE - 130k
Audi S3 Black Edition Quattro (2020) - 11k
ZZR1400 (2010) - 55k
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out through a small hole somewhere. Much quicker not to do that.
