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Peugeot 306 2.0 HDI (YEAR 2000) 5406.02 WHEEL SECURITY BOLT LOST SOCKET AND REMOVAL

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I never lose anything! I laughed when my mate lost the socket for his McGard security bolts. Now, I've gone and lost the socket for my 306 wheel security bolts.

I always use a torque wrench when I fasten my wheel bolts. The torque wrench setting is 85Nm for the 306 HDI.

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↓ This is the type of security bolt that is on my X reg 306 HDI.

Peugeot Ref. 5406.02

 

 

↓ This is a view of the security bolt looking down the hole in the wheel. I could not remove the bolt so I had to measure it up just by looking at the top of it which was 30mm down in the bolt hole in the wheel. It was difficult to say the least.
The special socket that comes with the security bolt kit has four pins that engage in the four holes in the head of the security bolt.
On my set, the holes are roughly at 12 o'clock, 4 o'clock, 6 o'clock, and 8 o'clock.
Each set of security bolts has the four holes placed at different points around a circle.
It should not be too hard to make a new socket to fit the hole pattern.

 

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↓ I used a washer from a Tap Connector to obtain the location of each hole.

 

↓ I placed the tap con washer on the bolt head. I placed the end of a thick walled tube against the washer. I hit the tube with a hammer. This pushed the washer hard against the bolt head and left an imprint of the four holes on the washer.

 

↓ I machined a short bar of metal in the lathe. This would become the special socket.
I transferred the hole locations onto the end of the bar and drilled 4 holes.
In this picture you can see the holes are roughly at 12 o'clock, 4 o'clock, 6 o'clock, and 8 o'clock.

 

↓ I placed the socket back in the lathe and proceeded to bore a circular recess 9mm deep.

 

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Socket Diameter = 31mm.
Socket Length = 38mm.
Hole Diameter = 4mm.
The centre of each of the four holes lie on a circle, 19mm diameter.

 

↓ I stopped boring when half of each of the four holes was removed.

 

 

 

↓ I made four pins to fit the holes.

 

Later on, I brazed the assembly using silver solder.

 

↓ I then realised I had made a mistake. The socket was 38mm long, but this was far too short.
I should have made the socket out of one piece of bar, 114mm long, but I did not want to start over again.
I had to make an extension, so I could get a wrench on it to undo the bolts.
↓ This is the extension piece. It is 76mm long.

 

↓ The socket and extension piece are joined by three 8mm pins.

 

↓ I bored three mating holes in the socket.
The threaded hole in the middle of the socket was already in the scrap piece of metal bar.

 

 

 

↓ This is the finished assembly after it was brazed up and used.
I ended up using three pins instead of four. My marking out was wrong and the socket would not fit the bolt when all four pins were in place.

 

↓ The tool does not look pretty but it did the job and removed all four security bolts.
The score marks were made by my Record Stillson 24 inch wrench.

 

 

 

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