Brambles Posted March 11, 2022 Share Posted March 11, 2022 Derek, Oh good you have found them. I could not find them searching online to get the size of Torx driver bit needed. Now we know. T30. I was going to go out to my motorhome to check this morning but no need now. Link to comment Share on other sites More sharing options...
Derek Uzzell Posted March 11, 2022 Share Posted March 11, 2022 Bjorn attached a drawing to his posting of 9 March 2022 12:53 PM and I've copied this below. I assume the torx bolts are shown on the drawing as Part 1 (arrowed in red) and that there are four of them. Logically, the bolts' function will be to secure the lower edge of the bumper firmly to the cross-member - otherwise the bumper would have limited structural integrity if it got 'bumped'. Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 11, 2022 Share Posted March 11, 2022 Derek, Brambles thanks for the info, its hard to see what they were when your under the van. I thought they might have been hex bolts like they love using on modern vespas. Mine also have a rubber grommet between the head and the bumper. Will give it a go at lunchtime. Well did a bit of prep yesterday while waiting for the crossmember to come and the bit that holds the pipe is rotted off so it should be fun getting that off the pipe! I had a peak to see how to support the rad then I discovered the top radiator mounts are shot. Probably caused by the radiator dropping due to the corrosion on the crossmember. So onto the tinternet for them then. I'm thinking to get a bit more space under the van (fed up with scraping my nose on the bottom of the van when I turn my head) using my levelling chocks to raise it a couple of inches. I am so glad I looked at this before the season starts. The vans first trip is in two weeks all the way from Glasgow to South Wales. Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 11, 2022 Share Posted March 11, 2022 just for info the jump in price when you get them here! https://www.ferrariparts.co.uk/part/maserati/51810310?id=181123 £2.40 radiator mounts ordered don't come till Wednesday :( well it will give me time to get the bumper screws out and have a bash at freeing hose guide from chunk of rust its still attached to. Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 11, 2022 Share Posted March 11, 2022 they are a t 2.7 on my van and rotten. looks like they will need drilled out or cut out Link to comment Share on other sites More sharing options...
Brambles Posted March 11, 2022 Share Posted March 11, 2022 Bjorn Toulouse - 2022-03-11 4:09 PM they are a t 2.7 on my van and rotten. looks like they will need drilled out or cut out Sounds like you are having a lot of fun with this repair...and you cannot use heat on them because of the plastic bumper. As they are rusty and its anew cross member then best just to drill out and replace with new ones. £1.99 each on Ebay. Just remember to say "I win and you lose " to the Motorhome every time you get a bolt out. It will help you from getting frustrated with the repair. Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 14, 2022 Share Posted March 14, 2022 Drilled out. Now I need to find bolts that will fit. Link to comment Share on other sites More sharing options...
Brambles Posted March 14, 2022 Share Posted March 14, 2022 Found on Ebay. https://www.ebay.co.uk/itm/174601016391?hash=item28a7081447:g:zfoAAOSwF9JgBVF1 Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 16, 2022 Share Posted March 16, 2022 Well crossmember out........ Next problem is the wiring clips (4 of) that attach to the crossmember. well they appear to be riveted on. Just buy new clips? Both the Fiat and the Peugeot dealers cant find them on their schematics. Sorry cant help. The hole they go into is just larger than an m6 any ideas? Link to comment Share on other sites More sharing options...
Derek Uzzell Posted March 16, 2022 Share Posted March 16, 2022 Are you referring to the arrowed things in the attached image or to something else? (I notice that "oversize cable clips" were mentioned in this 2020 Fiat Forum thread that described removal of the crossmember.) https://www.fiatforum.com/threads/ducato-2005-cross-member-hose-clamp.480036/ Link to comment Share on other sites More sharing options...
silverback Posted March 16, 2022 Author Share Posted March 16, 2022 zip ties? Link to comment Share on other sites More sharing options...
Derek Uzzell Posted March 17, 2022 Share Posted March 17, 2022 GOOGLE-searches on "automotive cable clips" and "crossmember cable clips" produce the following results https://tinyurl.com/446azra6 https://tinyurl.com/2ju324dm Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 17, 2022 Share Posted March 17, 2022 Derek, that's the chaps. It ends up that they were some how riveted on with the strangest rivets I have ever seen. I popped the the rivets by smacking them where the clip meets the crossmember with a chisel. They came off fairly easily. once off used a 5mm drill to tap the remainder of the rivet from the clip. Once off I drilled 4 4mm holes next to the ones already on the crossmember and pop riveted them back into place. Next up the metal curved cable protector and plastic box. I think I will just cable tie this using 4 Heavy duty cable ties. One thing I have noticed is there are a lot of holes on the top of the crossmember and only 4 spare on the bottom. The 4 that are spare have a threaded nut welded on the inside. The ones on the outside are for attaching the bumper. So I can see plenty of ways for water to get in but no real way for it to get out. No wonder they rust. Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 17, 2022 Share Posted March 17, 2022 Brambles - 2022-03-11 8:03 PM Bjorn Toulouse - 2022-03-11 4:09 PM they are a t 2.7 on my van and rotten. looks like they will need drilled out or cut out Sounds like you are having a lot of fun with this repair...and you cannot use heat on them because of the plastic bumper. As they are rusty and its anew cross member then best just to drill out and replace with new ones. £1.99 each on Ebay. Just remember to say "I win and you lose " to the Motorhome every time you get a bolt out. It will help you from getting frustrated with the repair. The other job I have been attempting is change the back tyre on a vespa lxv 125. This is a walk in the park comparing to that. I have been at that for 9 months off and on! Link to comment Share on other sites More sharing options...
silverback Posted March 17, 2022 Author Share Posted March 17, 2022 One thing I have noticed is there are a lot of holes on the top of the crossmember and only 4 spare on the bottom. The 4 that are spare have a threaded nut welded on the inside. The ones on the outside are for attaching the bumper. So I can see plenty of ways for water to get in but no real way for it to get out. No wonder they rust. Bjorn what I did on the bottom of the cross member to get rid of the water was to drill 2 holes 5mm dia in the middle for the water to run out Jonathan Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 17, 2022 Share Posted March 17, 2022 thanks Johnathan, might make them a little larger and at the offside (van always parked in the same place) a couple of picks Link to comment Share on other sites More sharing options...
Bjorn Toulouse Posted March 21, 2022 Share Posted March 21, 2022 Now fitted, next step fix the window. Link to comment Share on other sites More sharing options...
Brambles Posted March 21, 2022 Share Posted March 21, 2022 Bjorn Toulouse - 2022-03-21 1:26 PM Now fitted, next step fix the window. Well done. What needs fixing with the window? Link to comment Share on other sites More sharing options...
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