Information on Removal of Luggage Carrier Rail Assembly Bolts Strip Out and/or Heads Break Off When Removing While Installing RIA Luggage Carriers

The purpose of this bulletin is to communicate some helpful tips to use when removing the Luggage Carrier Rail Assembly Bolts and removing the bolts, if they do strip and/or the heads break off.

1. Do not use pneumatic tools to remove bolts. Use hand tools only.
2. Use only a #25 Torx bit, not a #25 Torx Plus bit. These bolts are not Torx Plus. Using a Torx Plus bit will not engage the cavities inside the bolt head properly and will actually enhance the chance of slipping.
3. Make sure the #25 Torx bit used is in good condition and from a professional grade tool supplier. General use bits may not hold up to the torque needed to remove the bolts.
4. When removing the bolts make sure to keep the bit fully engaged in all the bolt head cavities and perpendicular at all times. Allowing the bit to move slightly off center will allow the bit to slip.
5. When first beginning to remove the bolt, use short slow stokes with the ratchet until the bolt begins to move freely.
6. When a bolt appears to be hard to turn, applying heat to the head of the bolt for approximately 45 seconds to a minute with the tip of an electric soldering iron/gun, or something equivalent, will help loosen the threadlocking substance to aid in removal.

Notice: Be careful to not allow the heat source to produce enough heat to begin deforming the Luggage Carrier Rail Assemblies.

Gain access to the effected fastener by removing the Luggage Carrier Rail Assembly at the effected fastener location. This can be accomplished by cutting through the Luggage Carrier Rail Assembly at an angle around the fastener and breaking off the Luggage Carrier Rail Assembly just enough to expose the bolt. Once the bolt is exposed, file flats on opposite sides of the head and use locking pliers to remove the bolt. If the head has broken off, follow the same procedure on the exposed threads.

Notice: Extreme caution must be taken to not cut clear through the Luggage Carrier Rail Assembly and damage the paint.

Remove the Luggage Carrier Rail Assembly at the effected fastener location. File flats on opposite sides of the exposed threads and use locking pliers to remove the fastener. IMPORTANT:

Important: Using a left handed 3/16" or smaller drill bit in a reversible drill motor in many cases will result in the remaining fastener unscrewing during the drilling process.

If the weld nut is damaged to the point where a tap will not restore the threads properly, follow the installation instructions from the L850 Timesert Kit (P/N J-42385-850) and install a M6X1.0 Insert (P/N J042385-205).

Important: Use of thread locking material is critical for installation of Timeserts and the roof rack bolts. For Timeserts use Loctite 277 Threadlocker and for roof rack bolts use Loctite 242 Threadlocker.

In the event a bolt head strips out or breaks off or a nut is damaged in bolt extraction, a warranty claim may be submitted using labor operation A9220 - Repair Roof Panel. NOTE: This labor operation is assigned a time of .5 hours. If less time is required, please reduce. If more than .5 hours is required enter the additional time in "other hours". This repair must be time stamped separately on the CSO hardcopy and be authorized by the Fixed Operations Manager.