Triumf 24952 User manual

24952 Broken stud M8 remover kit with press function, version Nr.1- y.2016
Security precautions
To understand the activities of the instrument is required in advance to read these instructions!
- Carefully and in the right order, please read this manual before setting - up the device
- At work, always follow the data in the instructions / maintenance manual manufacturer for
current information and steps in the right order
- The instructions for use and recommended tools in this set are as a guideline and it is no
guarantee for success
- This set contains special products, which was several times successfully tested and used
successfully. It is necessary to pay attention to the accuracy of compliance with the order of
the steps
- The device must only be used professionally
Set 24952 contains instruction manual + detailing photo documents.
Set is packed in EVA foam in plastic case.
All part are available separately.

Part list
Item nr.
Description
Q.
Triumf item
1
Short rail nr1 with arch
1
34910
2
Short rail nr2, straight
1
34911
3
Longitudinal rails with centering holes
2
34904
4
Centering tip D8mm, (yellow zinc)
1
34917
5
Centering tip D8mm, deep (blue zinc)
1
34919
6
Drilling tip D9mm, (green)
1
34918
7
Extra long tap M10 x 1,0 length 200mm
1
26399
8
Centering guide for tap 26399
1
35260
9
Long HSS twist drill Ø 9,0mm cobalt 5%, fully ground
4
12849
10
Short HSS twist drill Ø 9,0mm cobalt 5%, fully ground
1
35322
11
Spare stud Fiat Ducato 3.0
4
35069
12
Glue for threads 5 ml
1
5259
13
Inbus " T " handle keys, both sides, size 2340 2,5x150
1
35279
14
Inbus " T " handle keys, both sides, size 2340 5x150
1
35280
15
Combination spanner 22mm, DIN 3113
1
1110
16
Spring washer 8,2 Zn, DIN 7980
4
35221
17
Washer 8 DIN125 Zn 8.4
4
31096
18
Nut hex M8 Zn DIN 934
4
32018
19
Main drilling unit with press function
1
35259
20
Tap wrench
1
23953
21
Plastic case
1
35290
22
EVA foam
1
35281
Picture1. Set 24952 –Part list

Problem localization:
Set of special tools is suitable
for light commercial vehicle
with engine 3,0l:
Engine code F1CE-3,0l in:
Fiat Ducato
Iveco Daily, Massif
Peugeot Boxer
Citroën Jumper (Euro 3, 4 & 5)
Mitsubishi Fuso Canter
Diesel injectors of the engines mentioned above are fixed by bolt M8. The bolts of all
injectors are situated in the camshaft cover recess, which is on the right end in the cover
camshafts with drainage groove. Drainage groove serves the water remowing which has
flowed through a leak between the windshield and the hood. This technically imperfect
solution to drain water causes water retention around the injectors and injector bolts which
penetrates and settles between the steel bolt and the head of the cast, where bolt formed solid
precipitate in the height of 22 mm. It cannot be chemically removed; it can be removed by
manually linkages breaking.
Picture 2. Dismantled cylinder head of engine Fiat Ducato HPi 3.0l
Picture 3. Cylinder head cross cutting view Fiat Ducato HPi 3.0l

Said in other words. Thread is a cylinder head around 20 in length (28 mm as shown
picturenr.3) and sediment - corroded joint 32 mm.
Such a large rust resistor cannot be overcome to release with 13 mm sockets and in most cases
tear off the head bolts in all 4 injector holders also the new vehicles.
The follow drilling out process is very complicated because the bolt is made by rolling the
compacted material especially at the point of the thread, between the beginning and the bolt
body. (Bolt hardness 10.8).
Inproper free drilling out done by hands in wrong speed without cooling and without
removing chips also with inaccuracies drill heads almost always results in imprecise drilling
and break the cylinder head wall. So it should not fully drill out of original thread or drilling
the water canal, which is located just below the end of the bolt.
Drilling out broken stud takes three hours also for manualy operation skillfully workers, (for
all four injectors 12 hours).
Mechanics also make this operation simpler. Work can be fastening by drilling stud the
injector after removing the cylinder head. It brings with additional time and costly action such
as draining coolant, replace head gasket and others.
When stud is drilled out, the tolerance goes away. Injector retaining bolt has original thread
M8x1,25. It is insufficient and therefore it is necessary to stocking threaded inserts "Helicoil"
(spring system). Mechanics facilitate their work and incorrectly insert coil into the camshaft
cover because of elaborateness and complexity of the operation. But it is wrong.
Solution
The solution to this issue is The drill out device - manufactured by Triumf with order number
24952.
Picture 4. Injector fixing bolt Fiat Ducato HPi 3.0l
Picture 5. Body of drilling out mechanism from set 24952

Despite the time consumption associated with dismantling workspace is time saving as well as
a guaranteed result of the work. The working comfort is unparalleled advantage with the time
required for removal of the above-mentioned parts.
Before installation of drilling mechanism is necessary to dismantle the injector in order to
properly drilling block centering with respect to the exact positioning or centering and drilling
tip for broken stud M8.
The process of removing the original stud including new stud installing is a matter of minutes
(10-15 minutes).
Tool construction:
The base of stud drilling out set are 4 rails that create the support frame with pre-drilled holes
on the localization longitudinal rails. Then you install drilling out mechanism where the final
position of drilling out block can tune / finely set the centering flap. It allows removal and
insertion of the drilling unit or use correction tap without re-setting the individual parameters.
Workers can continue his work where was interrupted and begin there. During the work it can
be easily lubricated, removing chips and control of the drill tip.
Downforce actually in drilling out is balanced due to the leveraging mechanism. Drill
machine is still at the same angle thanks to centering sleeves.
Position of drill machine is aligned with guide sleeves. Force transferring also in higher
pressure is smooth, given the installed bearings.
Picture 6. Detail photo injector retaining bolt M8x1,25

If injector is dismantled, we are recommended to blind injector holes with special tool - order
No. 23542 (blind hole injectors cap Ø10mm, shaft 7mm, 6x plus insertion tool - not included
in the kit) and the remaining holes, hoses, tubes sealed and cover with cloth.
All visible engine parts that could prevent proper installation and use of the products must be
removed from the work area.
The following photo documentation shows removed and dismantled cylinder head and
cylinder head prepared for mounting of drilling out mechanism for stud removing and
remowing the most important parts that could mislead at work
Picture 7. Before installation drilling out block must be removed engine components such as fuel
lines, electrical wires, air ducts and others.
Picture 8. Injector hole blinding tool for Fiat Hpi 3.0l
Picture 9. On the left is dismantled cylinder head of Fiat Hpi 3.0l, right dismantled engine parts needed
for installation drilling out mechanism from set 24952

Installation procedure of drilling mechanism
1 Support rails installation for drilling mechanism
TIP: Rails are selfcentering. Rail centering is not necessary, since the holes are precision pre-
driller.
To make faster and easy to install drilling mechanism are all screws with inbus head 5mm.
Rails contain also predrilled holes M8.
All rails are designed to not cause any confusion to change by each other. This way you do
not use force for proper installation and therefore do not force or increased their strength in
the assembly. Therefore, these components made of lightweight aluminum profiles.
1.1 Dismantle by T handle 5 mm Allen key (# 12), two original screws on the left side of the
cylinder head (see detail red circles to indicate the location of the screws).
Picture: Cylinder head of engine Fiat 3.0 diesel
1.2 Fit rail nr.1 on place of two removed scres. This rail is in its middle part specially shaped
to provide space for drilling out of broken stud on the first cylinder. C type of rail towards the
Picture 10. Screw position, neccesary remove for installation rail nr.1
Picture 11. Remove 2 screws using T handle allen key nr.14 and fittinng rail nr.1

inside of the cylinder head. Place rail nr.1 in screwing by original bolts using T Allen key size
5 mm (No.14) to the rail.
1.3 Fit the rail nr. 2 on the opposite side (right side of the cylinder head near the cylinder No.
4). Rail nr. 2 is placed parallel to the rail nr.1, that is in its upright position. This rail, in
contrast to rail No. 1 has no special molding shape. Correctness of this rail is given / provided
rounded corners moldings facing outwards from the cylinder head. For fixing rail No.2 use
screws that are part of this bar and are therefore part of the set 24952. set screws are screwed
firmly by T Allen key 5mm (No. 14).
Note: Bolts of rails No. 1,2,3 need to be tightened by hand. Accompanied T Allen key is fully
sufficient to tighten these screws.
1.4 Fix rear rail (one of a pair of rails no. 3) with two recesses in the middle of the ends of the
seats already mounted rails No.1 and No.2. Rail directs towards the protrusion in the engine
cam housing. The rails are elongated threaded holes M8, which will subsequently be used to
adjust the position of drilling mechanism for each injector to mount the base plate of drilling
block.
Correctness of this rail is given by rounded corners at the rear. This rail can not be fitted on
the contrary. Direction is done the sustainability of logs in the rail with respect to the shape of
the cam housing. Install rail by two screws, which are part of the rail. Tighten the screws with
T Allen. key 5 mm (No. 14).
1.5 Install the last - the front rail (second bar of the pair of long rails, the number 3). This rail
does not contain any recesses and notches. The accuracy is determined by the round edges
towards the outside of the mounted frame, consisting of 4 rails. This frame is used for
Picture 11. Installation of rail nr.2 using by screws with 5mm allen head.. (rails already contain screws)
Picture 12. Mountings the rear rail No. 3 on the already placing rail 1 and the nr2.

installation drilling out mechanism. All rails must fit properly in their recesses and outer
corners of the support frame of the drilling mechanism. It must be withheld roundly. Fit the
last rail using two screws (also part of this rail).
2 Prepare of broken stud and choose the correct centering tip
2.1 After the mounting rails is necessary to prepare a stud. Before installation of drilling
equipment must be stud cleaned at least slightly from corrosion or remove the mini angle
grinder or shaped visibly deformed part by slice of saw (but this is rare). The important thing
is to allow fit centering tip the short / long one (depending on the length of the pins) for the
protruding stud . Both tips are with a diameter of 8 mm.
2.2 If stud was broken in right high level and sufficiently protrudes above the cam cover is
sufficient for only a short tip (# 4) if stud is below the cover cams use the extended tip of the
cranked stud (6).
Before installation of drilling mechanism is necessary to dismantle the injector in order to
properly drilling block centering with respect to the exact positioning or centering and drilling
tip for broken stud M8.
Picture 13. Installation the front rail (one of a pair of rails No. 3) and then complet mounting support
frame for mounting drilling mechanism.

Broken stud is neccesary resurface, straighten the edges in the case stud is bent so to pass a
neck centering tip 8mm - tip # 4 or # 6, due to possibility of variant broken stud.
Tips dividing:
- yellow centering tip for broken stud (nr.4). 8mm –yellow zinc coating.
- blue centering tip for deep broken stud (nr.5). 8mm –blue zinc coating.
- green tip 9mm (nr.6)
Picture 14. Injector retaining broken stud Fiat Hpi 3,0l
Picture 15. Tip Installation of the drilling mechanism. Screw the tip using by combination spanner 22mm
(No.15).
Picture 16.Tips diversification

3 Drilling mechanism installation
3.1 Install drilling mechanism over the before fitted support frame in order to ensure centering
axis of drilling mechanism and broken stud. For broken stud centering with drilling
mechanism use a centering tip No. 4 or No. 5 (in case of deep broken stud).
3.2 Before installation of drilling mechanism just release 3 screws of stops (see red marked
round –2 screws are positioned in rectangular stops and 1 on triangular stop –picture 16).
Then we remove the handle by unscrewing screw with knurled flat head. Remove the screws
to separate the central part from base plate of the drilling mechanism (picture17)
Picture 16.Stops loosing on drilling mechanism
Picture 17.Handle removing from centre part of drilling mechanism (red marked round show the screws to
separate centre part from base plate of drilling mechanism.

3.3 Insert base plate of drilling mechanism to supporting the frame. Position base plate of
drilling block around the center of the broken stud M8. Put the screws to the base plate of the
mechanism, but do not tighten them it at this stage.
Loose stops 1,2 to install centre part of drilling mechanism. Drilling block has already
installed the correct centering tip.
3.4 Screw the right tip depends on the depth of the broken stud by using the combination
spanners 22 mm and then 3 screws connecting the base plate with middle and top part of
drilling mechanism.
Picture 18.Handle removing from centre part of drilling mechanism and separate centre part from base plate of
drilling mechanism by using T handle hex key 5mm.
Picture 19.Base plate placing on support frame of drilled mechanism build by 4 rails.
Picture 20.Stops screw loosing for installing middle part of drilling mechanism.
Insert base plate of
drilling mechanism
over the broken stud.
Then fix this base plate
with 4 screws (do not
tighten screws in this
stage).

3.5 When base unit was installed, tight the 4 screws of base plate (Fig. 19). which hold the
longitudinal rails. Final centering carried out by setting of stop blocks (Fig. 20) on the sides,
to facilitate remove and insert drilling mechanism without resetting the base plate and
centered position.
3.6 Force the stop no. 1 to the middle part of a mechanism. Firmly tighten is needed.
Also, we force the stop No.2 to this mechanism and tighten it.
Note: After tightening all screws you have drill mechanism finally centered in alignment with
the broken stud M8.

4 Drilling out of broken stud M8
When drilling mechanism is right centered, replace centering tip (8mm) for 9 mm drilling tip.
The tip is made of high quality hardened material, where there is no way to scuff interior
walls of tip. Tip will serve as a long time as a solid guide for drilling out broken stud M8.
The cylinder walls drilling mechanism are perfectly cut and polished, therefore greasing in
every use is very important.
4.1 This chapter comes with process of direct drilling out of broken stud. Remove 3 screws,
which connected middle part of drilling mechanism with base plate. Then remove middle part
and handle too (chapter 3, Picture 17). Previous steps are neccessary for replace centering tip
to drilling tip (no6). Fix drilling tip in its position using by spanner 22mm (combination
spanner 22mm –part from set, no15).
4.2 After replacing centered tip for the drilling tip 9mm (no6) set the top part of drilling
mechanism. Force it tight it by hand. Do not use adapters and extensions.
Note: Stops stay fully fixed. –FIX of centering position
of drilling mechanism for broken stud. Middle part is
placed and forced to the fixed stops. After that screw and
tight 3 screws connected centre part of mechanism with
base plate.
Picture 21.Drilling tip installation no. 6 using by spanner 22mm no15 + detail Picture of drilling out bushing to
broken stud..
Picture 22.Centre part installing to the centered base plase of drilling mechanism.

4.3 Drilling process
The set order no 24952, you have purchased contains cobalt drills with respect to screw
material the injector.
Drill material is the most proven in compare with other types of drills. The set contains drill
bits of the same diameter but different lengths. Short drill No. 10 is used for the initial drilling
out the stud, which stick out over the camshaft cover and the other length drill (4 drills with
exact length), guarantees 100% stud drilling out with no water canals damaging.
In final stage the original injector retaining screw M8x1,25 will be replaced by new stud
No.11. New stud is ended hexagon top for its easy installing. New stud fixed by nut prevents
or avoids the problem in removing injectors for next time. The operator will no longer face
the problem broken stud. Nut is situated always above the potential water level.
New stud in process of nut removing is hold by 6-point end, allowing comfortable loosening
the nut.
4.4 Drill installation
In case broken stud M8 sticking very high above the surface of the cams cover use short drill
for initial drilling (No.10). Set contains only one short drill, because the protruding part of
broken stud is not rolling and thus softer than the lower part of this screw.
After drilling out long stud replace short drill bit for a long drill.
Note: Remember, if you'll re-sharp of long drill, you may not be sufficient for a total length of
drilling. Not recommended to use re-sharpening long drill more than 2 times.
4.5 Mount cobalt drill with slotted part at the end of shank to the extended cavity for drilling
mechanism and fix it by T hex key 2.5 mm (No.13). Tight the grub screw that secure drill
position in extended housing mechanism. The contact slotted surface of drill is sufficiently
large to avoid drill twisting also at higher pressure.
Note: Install cobalt drill in size 9 mm so as to fit the area on the shank of the drill hole
directed to the extended drill spindle.
Installed drill insert through the tip No. 6. Screw 3 screws to secure the center part of drilling
mechanism and base plate. Fix handle mechanism and then connect the drill.
Picture 23.Spare stud, include in set 24952 no.11
thread M8x1,25
Hexagonal ended

4.6 Now connect drill machine (electric or battery) and set speeds ranging from 500 to 800.
Start drilling out process with a gradual constant pressure on the handle. Apply pressure
through lever mechanism for drilling out broken stud. In drilling process does not exceed drill
speed 1000 rotation per minute.
Make frequently greasing and metal chips removing during the drilling process. We
recommend vacuuming chips, blow by compressed air and remove with magnets. Moderate
and continuous downforce aims for fully drilling out the broken stud M8.
Note: One broken stud can be drilling out by one of factory sharpening drill.
Drilling mechanism is designed that it is possible to eliminate inaccuracies in drilling by
hands or pillar drill machine.
Picture 24. Drill bit installation into the estended drilling spindle for drilling mechanism.
Picture 25. Installing appropriately selected drill and tighten the three screws of center part of drilling mechanism
milled surface on drill shank for accurate installation of the drill

I. Knurled presser handle ensures a firm grip even
with greasy hands of the operator –non slip effect.
The sliding mechanism includes a bearing, thanks
to lever movement is smooth and easy
II. Dual lines lever of sliding mechanism ensures
increased rigidity and high resistance.
III. Handle of drilling out mechanism can be easily
separated from the rest of unit by unscrewing the
bolt with round knurled head - no need spanner.
IV. For removing the metal chips pull the handle to
its upper position to open the cavity for blowing,
vacuuming or removing with magnet. Removal of
material chips is possible through side vents, as
well lubrication and cooling.
4.7 After the drilling of pull out the drilling mechanism. The bottom base plate remains on its
place. Clean drilled area thoroughly, remove chips using magnet of blow out by compressed
air. Then clean drilled hole using brake cleaner and get ready for use thread contact adhesive.
Picture 26.Broken stud drilling out process

4.8 Drill intermittently with proportional downforce. Pull the handle over while drilling for
breakage of the chips. The drilling out process is performed intermittently, cold it by air and
oil. In the actual drilling made to handle optimal pressure.
Note: The speed of drill machine should not exceed 1000 rotation / min. Too high speed will
cause drill overheating and drill is no more function.
!!! Drilling out process –cooling by oil and air.
Picture 27. Drill machine connect
Picture 28. Vŕtanie s miernym prítlakom. Možnosť obojsmerného natočenia odvŕtavacieho mechanizmu.

After drilling out of
broken stud clean hole
off metal chips any other
residues. Remove center
part of drilling out
mechanism. Prepare the
tool for M10x1 thread
tapping.
Picture 29. Joints cleaning and oiling and blowing metal chips by compressed air
Picture 30.Greasing of drill spiral flute
Picture 31.Fully drilled out broken stud Fiat Hpi 3.0l

Picture 32.Detail fully drilled out broken stud M8 Fiat Hpi 3.
Picturec32. Cross view of cylinder Fiat Ducato HPi 3.0l