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The CAD design for the shoulder bolt & washer setup (frame to base plate) on the lower assembly tools is not representative of the actual tooling. The M10-1.5 shoulder bolt is modeled with a 1.15mm undercut, with engagement into a M10 precision ID flat washer of 1.35mm. This is not accurate. The purpose of the precision ID washer is to ensure the shoulder of the bolt has land to tighten down against for the full diameter of the bolt. The precision washer specified in the CAD design is 2.5mm thick as represent. Per the CAD, it would have 1.35mm of engagement with the threads of the bolt. Since the bolt actually has a 4mm undercut , not the 1.15mm modeled, the washer has no engagement with the threads of the bolt. This allows the ID of the washer to float freely outside the OD of the shoullder bolt. In addition, the washers are being coined downward upon tightening the shoulder bolts. This is the result of the allowable washer float & the lack of material underneath the washer. There is a threaded insert installed below the washer & it is set 0.5mm below the contact surface of the base plate. Note: This was found to be a contributing cause of no float conditions on the lower assembly tools @ Defiance – BAD! To correct this situation, change the washer to a reduced ID extra thick M10 washer; McMaster Carr OC: 98040A106 (Metric Black-Oxide Stl Extra-Thk Flat Washer M10 Screw Size, 10.5mm Id, 23mm Od, 4.5 mm-5.4 mm Thk). This eliminates the washer float & the extra thickness prevents coining. Defiance has converted their tooling & it has resolved the issue. Note: Block Work Request is CT03547

File Attachments:

	File Name	Description	User Name	Upload Date
Delete	TCR25700.ppt	TCR 25700	Hilvers.A, Alan (kzzp6x)	9/5/2006 11:41:15 AM

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Primary Part Information:   Select*

Program	Part Type	Part #	Design Phase	Location	PTE	Status
Inline 5	Head	12578265	Prod	Defiance	Hilvers, Alan	Accepted

Impacted Part Information:

Program	Part Type	Part #	Design Phase	Location	PTE	Status
Inline 5	Head	12563261	Prod	Defiance	Hilvers, Alan	Waived
Inline 6	Head	12579960	Prod	Saginaw	Noga, Gregg	Waived
Inline 6	Head	12586656	Dev	Saginaw	Noga, Gregg	Waived
Inline 6	Head	12601753	Dev	Saginaw	Noga, Gregg	Waived

Location Information:

Location	TM	Approval Date	Priority	Status
Defiance	Meyer, Maurice	1/4/2011 8:50:53 AM	Normal	Approved
Saginaw	Bujouves, Jim	2/20/2009 7:15:56 AM	Normal	Approved