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1. MOUNT THE PROPLATE™ to the manifold or turbocharger set for repair using the included ProFasteners and included mounting schematic. Torque ProFasteners to 40 FT-LBS. • Use the long ProFasteners included in the kit for the Turbocharger & Turbo-side of the manifold. Use the shorter ProFasteners for the EGR-side of the manifold.
INSERT THE PROBUSHING™ into the ProPlate™. Then insert the corresponding ProDrill™ machine grade tooling bit (included) into an air or electric powered drill. Set the proper depth of the bit: • For the EGR-side: use the drill depth gauge, machined into the ProPlate™. For the Turbo-side of the manifold: set the drill bit to 1.5” and mark if necessary. Apply one drop of ProLube™ (PPL001).
SET THE CUTTING EDGE (CRITICAL STEP TO AVOID BIT FAILURE AND MAINTIAN PRECISE ALIGNMENT) - Apply light pressure at first by activating your drill both on and off five times in one second intervals. This step creates a seat centered in the damaged bolt and reduces walking of the tooling bit even when drilling an angular surface. Moreover, this step ensures a perfect match between the surface of the broken bolt and the cutting edge of the bit which distributes the load evenly across the bit’s cutting edge.
MACHINE THE DAMAGED BOLT - Drill continuously at the proper RPM (see cutting speeds below). Once complete, extract the drill bit from the bushing and remove the bushing from the ProPlate. Using shop air and eye protection, blow air into the drilled hole, clearing it of debris and chips. Screw in your next sequential ProBushing and repeat steps 3 thru 5 machining the stud completely out (keeping cutting speeds in mind with each drill size). After drilling out the stud you may be able to use a pick to pull remaining remnants from the threads inside the manifold. Doing so will assist in a smoother operation in step
CHASE THE THREADS and return the bolt hole to factory-new condition. Screw in the largest ProBushing™ and attach the included ProTap™ into a 3/8” drive tap socket. Guide the tap into the bushing and slow turn the ProTap clockwise one full rotation at first or until you will feel resistance on the tap as you turn it – never force the tap). Reverse your ratchet and turn the tap counterclockwise ¼ rotation. Using shop air and eye protection, blow down each of the four tap flutes clearing debris. Repeat this process unit the tap stops at the bottom of the hole.
TIP: The manifold is often heavily corroded. Use a wire brush and aggressively clean the back side of the manifold and Turbo mounting area where the ProFasteners will seat.
TIP: You will need to apply pressure to the drill while machining out the broken bolts. ProMAXX Tool recommends using a drill chuck that is key tightened to reduce bit slippage rather than hand tightened.
AVOID USING PENETRATING OIL/SPRAY OR OTHER LUBRICANTS WHICH ELEVATE CUTTING EDGE TEMPERATURES CAUSING THE BIT TO BURN AND CEASE CUTTING.
Approximate tooling cutting speeds (Under load):
SSSC125/PLT125@500 RPM - SSSC188/PLT188 @ 300 RPM - SSSC266/270/ PLT270 @ 250 RPM - SSC345 @ 200 RPM