16‐03‐003BUG – Aluminium Reference Plate becoming loose – 2006-2013 Bugatti Veyron

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March 23, 2016 NHTSA CAMPAIGN NUMBER: 16V166000

Automobile Jacking Plates may Loosen and Detach

If these jacking plates separate from the vehicle while driving, they may be a road hazard, potentially striking another vehicle, and increasing the risk of a crash.

 

NHTSA Campaign Number: 16V166

Manufacturer BUGATTI

Components STRUCTURE

Potential Number of Units Affected 87

 

Summary

Bugatti is recalling certain 2006-2010 Veyron vehicles manufactured March 10, 2006, to March 9, 2012, 2010-2012 Veyron Grand Sport vehicles manufactured September 29, 2009, to October 14, 2014, and 2011-2013 Veyron Super Sport vehicles manufactured February 18, 2011, to August 17, 2012. In the affected vehicles, the underbody aluminum reference plates used when lifting the vehicle may corrode and detach from the vehicle.

 

Remedy

Bugatti will notify owners, and dealers will rivet and seal the underbody aluminum reference plates, free of charge. The recall began on May 26, 2016. Owners may contact Bugatti at (805) 557-1050.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 


Technical Bulletin
16‐03‐003BUG
RPS Plate

 

Applicability: 

Bugatti Veyron
Bugatti Grand Sport
Bugatti Super Sport

 

VIN range : 

As per E573

 

Market Region: 

All

 

Introduction: 

RPS plates on the Monocoque chassis have to be secured with rivets

  

Description: 

If the RPS plates of the Monocoque chassis are not riveted, check their position prior to securing them.

If the RPS plate of the Monocoque chassis is not present, a new RPS plate has to be installed

 

Warning: 

If any doubt regarding this procedure, contact your Bugatti contact.

Do NOT drive/move or lift the car within 24h of the repair. 

 

Procedure: 

  1. Check that the RPS plate is not dislocated from the monocoque. The RPS plate must not move during the hand verification (Do Not use tools). If the RPS plate is not in place or is loose, see the RPS installation procedure below
  1. Mechanically clean the RPS plate and surrounding area as shown on Fig. 1

Mechanically cleaned RPS‐ PlateFig 1: Mechanically cleaned RPS‐ Plate (Surrounding and bottom surface)

 

  1. Install the drilling gauge as shown on RPS installation drawing (Fig. 2), check the gauge position (Fig. 3‐5) prior to securing.

View from the bottom of the car, Schematic position of the fastening holes on all RPSFig 2: View from the bottom of the car, Schematic position of the fastening holes on all RPS

 

Installation position of the drilling gauge on the MonocoqueFig 3: Installation position of the drilling gauge on the Monocoque

 

Installation position of the drilling gauge on the Monocoque with Detail X stopFig 4: Installation position of the drilling gauge on the Monocoque with Detail X stop

 

Installation position of the drilling gauge on the Monocoque with Detail Y stopFig 5: Installation position of the drilling gauge on the Monocoque with Detail Y stop

 

Drill 3 holes

 

  1. Drill 3 holes dia. 5mm with max depth 30mm (including drilling gauge height) B. Monocoque or Fuel Tank could be damaged if not respected
  1. Remove drilling gauge and deburr holes (Fig.6(

RPS‐Plate with the 3 drilled and deburred holes (Ø5,0mm)Fig 6: RPS‐Plate with the 3 drilled and deburred holes (Ø5,0mm)

 

  1. Install and expand the 3 blind rivets Typ: Monobolt 2774 ø 4,8 mm (aluminum) with EPDM seal (Fig. 7‐9)

Avdel installation device Genesis nG3 with Monobolt Rivet 2774 with installed sealFig 7: Avdel installation device Genesis nG3 with Monobolt Rivet 2774 with installed seal

 

Remark : Alternative installation device:  

Pop Rivet Plilers V.A.G.‐ System Nr. VAS 1753 A with 72005‐02007 nozzle

 

Installation of the blind rivet with the Avdel installation device Genesis nG3Fig 8: Installation of the blind rivet with the Avdel installation device Genesis nG3

 

Riveted RPS Plate without surrounding sealFig 9: Riveted RPS Plate without surrounding seal

 

  1. Degrease the RPS plate surrounding with Brake Cleaner and let it dry for about 10 min
  2. Seal the RPS Plate surrounding with 3M Scotch‐Weld DP 490 (DA 001 730 A2) (Fig. 10‐11) with seal bead.

RPS Plate surrounding seal with Scotch‐Weld DP 490 (DA 001 730 A2)Fig 10: RPS Plate surrounding seal with Scotch‐Weld DP 490 (DA 001 730 A2)

 

Detail view of the RPS Plate surrounding sealed with Scotch‐Weld DP 490Fig 11: Detail view of the RPS Plate surrounding sealed with Scotch‐Weld DP 490

 

  1. Repeat sequence 1 to 8 for each RPS plates
  2. End of procedure

 

RPS Plate Re‐installation procedure:

  1. If the RPS Plate is loose, perform steps 2 to 5 of previous procedure
  2. Carefully remove the RPS plate, and mechanically clean contact surfaces between Monocoque and RPS plate with sandpaper grit 80 – 100
  3. Degrease the RPS plate and Monocoque RPS area with Brake Cleaner and let it dry for about 10 min
  4. Apply a thin film of the structural adhesive 3M Scotch‐Weld DP 490 (DA 001 730 A2) on the RPS Plate
  5. Install the RPS Plate on the Monocoque using drilling gauge installation bolt
  6. Install and expand the 3 blind rivets Typ: Monobolt 2774 ø 4,8 mm (aluminium) with EPDM seal (Fig. 7‐9)
  7. Remove drilling gauge installation bolt
  8. Seal the RPS Plate surrounding with 3M Scotch‐Weld DP 490 (DA 001 730 A2) (Fig. 10‐11) with seal bead.
  9. End of procedure

 

New RPS Plate installation procedure:

If the RPS Plate is not present on the vehicle, a measurement of the RPS insert has to be performed to select appropriate RPS Plate.

  1. Make sure the RPS tap is removed and clean the RPS insert with Brake Cleaner
  2. Use the depth probe of a Vernier calliper to measure the distance between the insert and the Monocoque Chassis

RPS Plate

 

  1. Repeat the measurement for the four measurement points of each missing RPS plate.

Record the measurement values

RPS Plate

 

  1. Calculate the average of the 4 measurements , and define appropriate RPS plate according following table (to be confirmed according RPS plate)

 

Average distance from Insert to Monocoque RPS plate thickness to be used
1,00 to 1,50 3,00 tbc
1,51 to 2,00 2,50 tbc
2,01 to 2,50 2,00 tbc
2,51 to 3,00 1,50 tbc

 

  1. Mechanically clean contact surfaces between Monocoque and RPS plate with sandpaper grit 80 – 100
  2. Install the selected RPS Plate on the Monocoque and the drilling gauge Drill 3 holes dia. 5mm with max depth 30mm (including drilling gauge height)

RPS Plate

 

  1. Remove drilling gauge and deburr RPS Plate holes
  2. Degrease the RPS plate and Monocoque RPS area with Brake Cleaner and let it dry for about 10 min
  3. Apply a thin film of the structural adhesive 3M Scotch‐Weld DP 490 (DA 001 730 A2) on the selected RPS Plate
  4. Install the selected RPS Plate on the Monocoque using drilling gauge installation bolt
  5. Install and expand the 3 blind rivets Typ: Monobolt 2774 ø 4,8 mm (aluminium) with EPDM seal (Fig. 7‐9)
  6. Remove drilling gauge installation bolt
  7. Seal the RPS Plate surrounding with 3M Scotch‐Weld DP 490 (DA 001 730 A2) (Fig. 10‐11) with seal bead
  8. End of procedure

 


Chronology :

In September 2011 during endurance tests a car was found to have a missing plate.

Knock tests were carried out on other internal and field cars and identified the presence of split corrosion and delamination between aluminium plate and carbon fiber monocoq.

The analysis was conducted and concluded – in January 2012

The repair solution was available internally – in February 2012.

On 11 of March 2016 the matter was brought to the product safety committee and a defect determination was made.

 


11 Affected Products

Vehicles

MAKE MODEL YEAR
BUGATTI VEYRON 2006-2010
BUGATTI VEYRON GRAND SPORT 2010-2012
BUGATTI VEYRON SUPER SPORT 2011-2013

 


13 Associated Documents

Remedy Instructions and TSB

RCRIT-16V166-5109.pdf 1074.295KB

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Recall Quarterly Report – 2016 Q2

RCLQRT-16V166-4274.PDF 214.496KB

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Defect 573 Report

RCLRPT-16V166-4494.PDF 30.544KB

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Recall Quarterly Report #5, 2017-2

RCLQRT-16V166-6283.PDF 214.89KB

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Recall Quarterly Report #3, 2016-4

RCLQRT-16V166-1302.PDF 214.688KB

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Recall Quarterly Report #2, 2016-3

RCLQRT-16V166-3900.PDF 214.594KB

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Recall Quarterly Report- Report #7, 2017-4

RCLQRT-16V166-5724.PDF 215.047KB

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Recall Quarterly Report #6, 2017-3

RCLQRT-16V166-8707.PDF 214.968KB

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Recall Quarterly Report #8, 2018-1

RCLQRT-16V166-5904.PDF 215.119KB

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Recall Quarterly Report #11, 2018-4

RCLQRT-16V166-1759.PDF 211.983KB

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Recall Quarterly Report #10, 2018-3

RCLQRT-16V166-4279.PDF 211.983KB

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Recall Quarterly Report #9, 2018-2

RCLQRT-16V166-3818.PDF 215.195KB

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Recall Quarterly Report #10, 2018-3

RCLQRT-16V166-1606.PDF 215.275KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=16V166&docType=RCL

 


 

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