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  1. #1
    Senior Member Two Rings
    Join Date
    Mar 09 2008
    AZ Member #
    26213
    Location
    Torrington, CT

    Snapped the mounting bolts on suspension top hats

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    So, two out of three of the bolts snapped when I was removing the top plate. I was replacing the control arms and it just seemed easier. . .

    Any reason I couldnít just drill them out and tap them with a slightly smaller bolt?

    Option 2 would be replacing the plate, but would require sourcing the plate and new bolts. On top of that, it would be much more disassembly.

    Thanks in advance for the input.


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  2. #2
    Active Member Two Rings tuna79's Avatar
    Join Date
    Mar 04 2016
    AZ Member #
    369756
    My Garage
    '12 S5 Prestige 6A, 03 C5 Allroad
    Location
    Space coast, FL

    Just to cover the basics, had you soaked them in PB blaster and hit them with a torch before snapping them? If not try that then attempt to extract them, if so then drilling out an tapping larger or helicoils are awesome.

  3. #3
    Senior Member Two Rings
    Join Date
    Mar 09 2008
    AZ Member #
    26213
    Location
    Torrington, CT

    Yep, tried that already, but it seemed like they were weakened already. Helicoils here I come


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  4. #4
    Veteran Member Three Rings
    Join Date
    Jun 07 2005
    AZ Member #
    6784
    Location
    Shepherdstown, WV

    They cost a little more (for good reason) but timeserts are a better option for the top plate (anything really). Since you use those bolts to line up the heavy strut assembly a helicoil maybe easily damaged or pull out.


    The cost of either though is barely less than just finding a top plate in the classified section. And not really anymore work.

  5. #5
    Veteran Member Four Rings 02 A6 2.7T's Avatar
    Join Date
    Nov 19 2006
    AZ Member #
    13513
    My Garage
    Too much crap
    Location
    WA

    Quote Originally Posted by beardman View Post
    So, two out of three of the bolts snapped when I was removing the top plate. I was replacing the control arms and it just seemed easier. . .

    Any reason I couldnít just drill them out and tap them with a slightly smaller bolt?

    Option 2 would be replacing the plate, but would require sourcing the plate and new bolts. On top of that, it would be much more disassembly.

    Thanks in advance for the input.


    Sent from my iPhone using Tapatalk
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    USED :
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    NEW :
    https://www.audiusaparts.com/oem-par...ket-8d0412383e
    2002 A6 2.7T - 6MT Crystal Blue APR Stage 1
    2002 S6 - 6 MT Black/black
    **SOLD ** 2002 allroad 2.7T 6MT

  6. #6
    Senior Member Two Rings
    Join Date
    Mar 09 2008
    AZ Member #
    26213
    Location
    Torrington, CT

    Those arenít the same. allroads need more holes on top for the air spring.


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  7. #7
    Veteran Member Three Rings
    Join Date
    Jun 07 2005
    AZ Member #
    6784
    Location
    Shepherdstown, WV

    Yes allroad ones are different and harder to find. In that case repair might be the better route. Although I bet you can find some ar ones in the classifieds easily.

  8. #8
    Senior Member Two Rings
    Join Date
    Mar 09 2008
    AZ Member #
    26213
    Location
    Torrington, CT

    Got a new top hat. Does anyone know the size of the bolts that hold this to the air spring by chance? They are torx or 12 pt triple square, but probably donít have to be.

    FYI, the bolts to hold the brace in are M10x1.5 25mm 10.9 bolts.


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