TURN, TURN, TURN: TORQUE WRENCH TECH BY MIKE MAVRIGIAN When fasteners must be tightened, many are too important to rely on a sense of feel. In these situations, the correct use of a torque wrench is essential. 34 June 2009 stationary needle that runs the length of the shaft handle. The needle indicates applied torque against a printed scale located at the base of the handle. This type of torque wrench offers no preset limit, and there’s no felt or audible “release” when a specific torque value is reached. The dial indicator type of torque wrench features a readout for visual display. Both the flex bar and dial indicator types provide visual displays of applied torque. The sound-indicating type signals applied torque by momentarily releasing the wrench a few degrees when the preset torque value is reached. The release is usually accompanied by a “click” sound. However, some release-type torque wrenches will release upon reaching the preset torque, but may not provide an audible click. The release/click type wrench is adjusted by means of a micrometer scale on the handle. When a torque wrench releases momentarily and/or clicks, this is referred to as a signal type. Indicator type refers to the visual display units such as the flex bar or dial indicator style. Any adjustable torque wrench should be set at its lowest torque reading when not in use. If left stored for long periods at a high-torque setting, the accuracy may be affected. When you’re done with a torque wrench, readjust it to the minimum setting before storing it in the toolbox. A torque wrench is a precision instrument that should never be used—abused!—as a pry bar or disassembly/assembly tool. It should be used to achieve final clamping load only. Handle all of your “wrenching” duties with common wrenches, and use the torque wrench only as the final adjuster to reach a specific torque level. When using an adjustable torque wrench, be careful not to overtighten by applying torque past the release point. At very low settings, the “click” may not be heard, especially in a noisy shop. It’s best to become familiar with the feel of the release, rather than to rely only on the sound of a click. When using an indicating type torque wrench (such as a flex bar or dial indicator type), try to read the indicator with a straight-on view of its surface. Reading the indicator at an angle will provide errors due to incorrect line of sight. Most torque wrenches operate accurately only when held at the center of their handle grips. Don’t use cheater bars to extend your grip farther away from the wrench head, and don’t grab the handle closer to the wrench head. Pick the Right Tool for the Job Not all torque wrenches are universally adaptable to all jobs. It’s important to choose one that features your torque value requirement in the middle of its range. For instance, if you need to tighten a fastener to 100 ft.-lbs., don’t use a torque wrench model that has an upper range limit of 100 ft.-lbs. Instead, use one that features a range of, say, 25 to 250 ft.-lbs. If tightening a fastener to 50 ft.-lbs., use a torque wrench that has an upper limit of about 100 ft.-lbs., and so on. So you may need torque wrenches with different ranges, depending on the type of work that enters your shop. To some technicians, this may seem like an unnecessary expense, but if you use torque wrenches at all, the whole point is to attain accurate and repeatable clamping values. So go the extra mile and maintain several torque wrenches, each with a different low-tohigh value range. The moral of the story: If you own only one torque wrench June 2009 35 Photos: Mike Mavrigian; visual effects: Harold Perry A torque wrench measures the amount of turning (rotational) force applied to a threaded fastener (nut or bolt). Torque wrench scales usually read in foot-pounds (ft.-lbs.) or inchpounds (in.-lbs.) and Newton-meters (Nm). Many torque wrenches provide dual scales, for reading in either English or metric format. With the foot-pounds scale, one foot-pound equals one pound of pull on a 1-ft.-long lever arm. There are three basic types of torque wrenches commonly used for automotive applications: flex bar, dial indicator and sound-indicating (micrometer). The flex bar type (also called the scale type or beam type) features a TORQUE WRENCH TECH Owning a selection of torque wrenches is a good idea. Shown here are (top to bottom) a 1⁄4-in.-drive in.-lb. wrench, a 3⁄8-in.-drive micrometer type ft.-lb. with a range of 10 to 100 ft.-lbs., a 1⁄2-in.-drive beam type and a 1 ⁄2-in.-drive ft.-lb. with a range of 20 to 250 ft.-lbs. that you try to use for a wide variety of work, you won’t be able to achieve accurate clamping loads for all jobs. Precision Instrumentation Another, very high-tech approach is to use an electronic torque wrench, an example of which is Sunnen’s computerized ETW-125 Sensor I. This high-precision torque wrench brings laboratory accuracy into the engine repairer’s and builder’s shop. This tool allows you to tighten a bolt to its torque-tension yield point without even knowing what the specs are. The wrench has four different tightening modes—angle control, where you can tighten to a prespecified angle (from the initial “snug” torque); torque control, where you can tighten to a prespecified torque; yield control, allowing you to tighten until the torque-tension yield point is reached; and dynamic torque A torque wrench that has been recalibrated and serviced should feature a label that indicates the service location and date of service. This will help to remind you of when the next recalibration service might be needed. audit, which allows you to determine the existing torque of a tightened fastener. The head of the tool features a strain gauge and a potentiometer that detects torque and angle, respectively. The body of the tool features an easy-to-read digital display and four control knobs. A reset button clears the memory and readies the tool for the next tightening task. A series of LED status lights provide instant information about the torquing operation. This is more than a glorified torque wrench, since the tool is capable of actually determining where bolt yield takes place, eliminating guesswork. The tool will not only find the precise yield point of a fastener, it will verify if a fastener is acceptable. In other words, it’ll find bad bolts. This tool eliminates the need for a connecting rod bolt length gauge, and offers the opportunity to reuse some torque-to-yield (TTY) bolts. If you can accurately verify that a TTY bolt is good, then it’s safe to reuse it. More on TTY bolts later. An electronic torque wrench also has the uncanny ability to determine the existing torque of a tightened bolt. It actually audits the torque of a fastener without the need to loosen it! According to Sunnen, the most effective way of auditing a fastener’s torque is to tighten the fastener further by a small, precise angle, then measure the instantaneous torque. It’s all a matter of complicated mathematical algorithms but the bottom line is that it does the job, and it’s very easy to use. Another firm, RS Technologies, offers an array of fastener verification equipment, referred to as “Torque-Angle Signature Analysis.” This sophisticated electronic equipment is compact (laptop size), and allows you to monitor fastener torque, angle, bolt elasticity and clamp- Always support the head of the torque wrench with your other hand (left photo), to help stabilize the socket angle at the fastener head. And always grip the wrench at the center of the grip area only (right). This provides increased accuracy. 36 June 2009 TORQUE WRENCH TECH ing force, with a special torque wrench fitted with a transducer hard-wired to the computer. I saw one of these units at the Perfect Circle machine shop school, and it was pretty wild. Watching the monitor, you can see exactly what the bolt is doing, as it happens. You can also save the information, make a printout or download it onto a disk. RS Technologies makes several of these systems. The most compact is the Model 960 Hand Held Transient Recorder. Thanks to advancements in technology, torque wrenches are now available that allow you to achieve both torque value and applied rotation angle without the need for a separate angle gauge. One example is Snap-on’s Techangle series of wrenches. Featuring sensor electronics and digital control and readout, you can preset (program) the torque value you want, or both torque value and final applied angle, depending on your needs. The electronic control allows you to also choose between in.-lbs., ft.-lbs. or Nm, plus angle. Two models are cur- rently available—ATECH2FR100, with a torque range of 5 to 100 ft.-lbs., and ATECH3FR250, with a torque range of 12.5 to 250 ft.-lbs. Torque wrenches with similar capabilities are available from Mac Tools, Matco, GearWrench and others. Recalibrating Torque Wrenches A busy shop should plan to have its torque wrenches recalibrated once each year at a minimum. Also, anytime a torque wrench has been dropped, it should be rechecked for calibration. Torque wrenches are delicate, precision pieces and, like the strings of a guitar, simply will not remain in perfect tune without care and routine maintenance. By virtue of the environment in which they operate, torque wrenches can be subjected to a great deal of wear. When used in an engine rebuilding shop that lives and breathes precision torque values, this wear level is at its zenith, even in the best-intentioned hands. While it’s certainly not recommended Circle #18 38 June 2009 to toss this precision instrument around the shop like a soccer ball, an occasional oops! may not cause severe calibration changes (we say “may” because it’s always possible for any hard impact to damage the tool). If badly abused, the wrench can be internally damaged if the impact force is severe enough. Bottom line: Don’t bang the thing around. Treat it for what it is—a precision instrument that deserves respect and care. The most compelling reasons to send your torque wrenches out for recalibration include life cycle and overtorquing. If the wrench is used very infrequently, it may require recalibration only every five years or so. However, if it’s used on a regular basis in a professional shop, the operating cycles increase dramatically. Depending on how much engine work your shop performs on a regular basis, the number of torque wrench cycles could easily reach 10,000 to 20,000 per year. When you add in the other miscellaneous torquing applications (oil and water pumps, exhaust manifolds, repairing shop equipment, etc.), even a small shop can easily run well over 20,000 cycles per year. When installing wheels (OE or custom aftermarket), final tightening of the wheel fasteners should always be done with a torque wrench, to manufacturer specifications. This is especially true with late-model thin-hat brake rotor hubs, since uneven tightening can lead to rotor disc warpage and a pulsating brake pedal. If your shop installs wheels at a rate of ten vehicles per day (for the sake of example, let’s say all of the wheels feature a five-bolt pattern), your torque wrench will experience about 200 cycles per day, or about 4000 cycles per month or 48,000 cycles per year. If a torque wrench is not used properly, accuracy can be affected, possibly resulting in overtorque (stretched cylinder head bolts or stripped bolt holes in the block, etc.), inadequate torque or uneven torque. Remember, when tightening a cylinder head’s fasteners, uneven or excessive bolt stretch can result in uneven or inadequate clamping. This uneven clamping force can lead to cylinder head warpage, coolant leaks, combustion leaks and even cylinder head cracking. When using any style of torque wrench, it’s critical to stop as soon as the desired torque value is achieved. In the case of a click-type torque wrench, stop applying force the moment the click is heard or felt. The typical user tends to stop too late, achieving about a 10% increase in applied torque. On a critical application such as engine assembly, this can create a real problem. For example, if the specified value is 110 ft.lbs. and the operator continually exceeds the “stop” signal, he could be applying 121 ft.-lbs. or more (and often in an uneven format, with multiple fasteners on the same component). Click-type micrometer style torque wrenches have an internal spring that’s preloaded via a screw adjustment when a new wrench is calibrated. When you feel or hear the click, you’re working against the spring and a cam mechanism. Overtorquing past the selected setting abuses the spring and will definitely cause an out-of-calibration problem. Torque wrench calibration has a finite life span. Every click on a torque wrench represents one cycle of use. All torque wrenches probably need to be recalibrated or at least retested after 5000 cycles (although some manufacturers recommend recalibration after as many as 10,000 cycles). Granted, 5000 cycles may seem like an extraordinary amount, but as we mentioned earlier, that level of use can easily occur in less than six month’s use in a machine shop. Most torque wrench manufacturers recommend that their products be recalibrated at least once each year under normal use. However, torque wrench operation in a busy engine rebuilding facility hardly qualifies as “normal” use. A Circle #19 June 2009 39 TORQUE WRENCH TECH A torque-plus-angle tightening specification involves first tightening the fastener to a specified torque using a torque wrench, then rotating the fastener head by an additional number of specified degrees. An angle gauge, such as this one by Lisle (shown in the left photo), will speed up the job (it’s faster and more accurate than painting a dot on the bolt head and guessing at the angle change). The photo on the right shows the angle gauge sandwiched between a socket wrench and a ratchet. The gauge body is anchored to a nearby stationary object via a flexible arm and clamp, to prevent it from rotating. routine recalibration schedule should be established for any shop’s torque wrenches. Another aspect of torque wrench use that can seriously affect calibration is bidirectional use—using a torque wrench in a counterclockwise direction in addition to clockwise rotation. When applying counterclockwise force through a torque wrench that was designed for clockwise rotation, you’re fighting a losing battle, because everything is stressed internally to favor the clockwise side. This left-hand application of force must overcome the built-in right-hand stress. Calibration on the left-hand side can be severely out-of-spec. The result is that you not only potentially damage the right-hand calibration, you also arrive at an unknown torque value when applying left-hand force. If you require lefthand operation, this can be specified when ordering a torque wrench (or when one is being recalibrated). If calibrated for left-hand pulls, the same wrench should not be used for righthand pulls. If your shop performs lefthand torquing on a fairly routine basis, it’s best to dedicate that torque wrench as your left-hand device, and label it accordingly, although I don’t see this as a common requirement for the average shop. Recalibration is required for all types of torque wrenches. Regardless of the design, all feature moving components that can stress or wear out. A great misconception with regard to torque wrenches relates to the ratcheting fea- 40 June 2009 ture of the click-type version. Some users commonly believe that the tool is a ratcheting wrench that also measures torque value. As a result, some users tend to use it to install as well as final-tighten fasteners. In reality, a torque wrench should never be used to initially install a fastener. The bolt or nut should be installed to “finger-tight” or “snug” force with a conventional wrench (fixed wrench or ratchet and socket), and final-tightened to value using the torque wrench. As for the cost of recalibration, not every recalibration service shop will charge the same amount. However, in order to gain a ballpark idea of this cost, I contacted the folks at Angle Repair Service (a premier torque wrench recalibration and testing facility in Beckley, WV, that’s used by a number of the leading wrench manufacturers). Angle’s typical recalibration fee is $25. Turnaround time is 24 to 48 hours, which means that for only $25, your torque wrench will be back in service in a heartbeat. Use of Adapters & Extensions As long as the adapter (socket extension, etc.) is in-line with the torque wrench drive, no compensation is required. However, if an adapter that effectively lengthens the wrench is used (such as a crowfoot wrench), a calculation must be made in order to achieve the desired torque value. For those occasions when a straight socket can’t be used, a special attachment might be needed (such as a crowfoot). The use of an offset adapter changes the calibration of the torque wrench, which makes it necessary to calculate the correct torque settings. Following is a method of calculating this change: E⫽Effective length of the extension, measured along the centerline of the torque wrench. L⫽Lever length of the wrench, from the center of the wrench drive to the center of the adapter’s grip area. TW ⫽Torque setting on the wrench. TE⫽Torque applied by the extension to the fastener. Formulas: L ⫼(L⫹E)⫻TE ⫽TW (where the adapter makes the wrench longer) or: L ⫼(L⫺E)⫻TE ⫽TW (where the adapter makes the wrench shorter) If you want to know where to set the torque wrench when using an adapter that alters the effective length of the wrench, you must calculate to compensate for the adapter. If the distance from the wrench drive to the center of the bolt makes the wrench longer, the final wrench setting must be adjusted to a lower value. If the distance from the wrench drive to the bolt center makes the wrench shorter, the wrench must be set to a higher value. Let’s say you want to torque a bolt to 140 ft.-lbs. but you’re using a crowfoot adapter. Let’s say the length of the torque wrench is 12 in. (from center of the handle to center of the drive). Let’s also say that the crowfoot is aiming away from the wrench drive, making the distance from the center of the wrench drive to the center of the bolt 1 in. This makes the wrench 1 in. longer. In this case, you’d divide the length of the torque wrench (L, from the center of the handle to the center of the drive) by L+E, then multiply that ratio by the desired value. In this example, the formula is: the connecting rod base material, at least consider the potential compression of the material itself during bolt clamping. As the bolt is tightened, the head of the bolt tends to embed itself into the rod, slightly compressing the stock material. Production rods are typically softer, allowing the head of the rod bolt to sink in, until the material under the bolt head work-hardens under compression. Torque-to-Yield Bolts 12⫼(12+1)⫻140⫽.923⫻140⫽129 So in this case, where the crowfoot adapter has made the torque wrench 1 in. longer, the wrench would be set at a value of 129 ft.-lbs. to achieve the desired value of 140 ft.-lbs. If the crowfoot is aimed toward the handle (turned 180° from the prior example), and we still want to achieve 140 ft.-lbs. of torque, we know that the adapter has now made the wrench shorter (because the center of the bolt is now closer to the center of the wrench handle), then the formula is: Using an extension extends the leverage point further than the torque wrench’s calibration, so you must use a simple formula to compensate for this extended leverage factor. Not compensating for the extension results in overtightening. 12⫼(12-1)⫻140⫽1.0909⫻140⫽152.7 So in this case, where we want to achieve 140 ft.-lbs. of torque but the wrench has been made 1 in. shorter, we adjust the wrench to a setting of 152.7 ft.-lbs. to actually achieve the desired torque of 140 ft.-lbs. In sum, if the adapter makes the wrench longer, you must back off on the adjustment setting. If the adapter makes the wrench shorter, you must raise the adjustment on the setting. The Friction Factor If a bolt is tightened using straight torque, the desired preload may not necessarily be achieved due to the variable of friction. Since we can’t predict the frictional loss, measuring rod bolt stretch provides the most accurate method of ensuring that the clamping loads will be sufficient for the task and that each pair of rod bolts will achieve equal loads. Bolt stretch is affected by a number of factors, including tensile strength and mass (the length of the bolt being stretched). The effective diameter of the bolt contributes to this. For example, let’s consider two 3⁄8x1-in. bolts. One fea- Wheel fasteners should be snugged initially. Here a speed wrench is used to initially tighten the wheel nuts, to make sure the wheel is mated flush with the hub face. Never use an impact gun for fastener installation. Final tightening should always be done with a torque wrench—no exceptions! Apply tightening in the appropriate crisscross pattern to evenly distribute the clamping load. tures threads on the full 1 in. of shank length. The other features only 1⁄4 in. of thread length at the tip, with 3⁄4 in. of the shank full diameter and smooth. The bolt with partial thread will stretch less, because the 3⁄4-in. shank area between the head and nut engagement area has a thicker cross section. The partial-thread bolt has a .375-in.-diameter shank, while the all-thread bolt has only a .324-in.diameter shank (due to the smaller root diameter inside the thread path). While we can’t control the reaction of Once, it was common practice to retorque cylinder heads after an initial engine break-in period. This was necessitated by the expected relaxation of the compressed head gasket after initial clamping. In far too many of today’s engines, this procedure of retorquing simply isn’t practical, due to the extremely difficult access to cylinder head bolts in a crowded engine bay. While it’s still easy to access the head bolts on a carbureted performance engine in a restored muscle car, it’s a real pain to perform this service on a late-model engine that features direct injection, a cumbersome upper intake plenum and a maze of wiring harnesses, plumbing and vacuum hoses. The engineering answer to this was the advent of the torque-to-yield (TTY) cylinder head bolt. When any bolt is tightened (any threaded bolt or stud, not just head bolts), it stretches by design. This is referred to as the bolt’s elasticity. This stretch creates clamping force; the more the bolt stretches, the greater the clamping force becomes...to a point. When the stretch enters the bolt’s yield point, the stretching (and therefore its clamping force) stops, and in fact begins to diminish. A TTY bolt will stretch to a point, retaining its elasticity, and will be able to spring back when tension is released. Once it’s stretched to its yield point, it stops generating tension. Stretched beyond that point, it will break. The same phenomenon takes place whenever a bolt is tightened. Ideally, we want to stretch the bolt to just short of its yield point. In that way, we take full advantage of its clamping force without yielding the bolt. When loosened, it will spring back to its original length, retaining its elastic property. A torque-to-yield bolt is designed to June 2009 41 TORQUE WRENCH TECH provide maximum clamping load on its initial tightening, since we don’t expect to return to the job by retorquing the bolts in order to provide more crush for a now-compressed head gasket. With a TTY bolt, we arrive at full “long-term” clamping load during the initial tightening process. When the gasket does relax, TTY bolts continue to provide sufficient clamping load to maintain an effective gasket seal. TTY bolts are designed to be tightened within a small window of tension—just short of their yield point. The torque spec for a TTY bolt is generally higher than that of a standard (nonTTY) head bolt, because we’re taking full advantage of the TTY bolt’s designed elastic range. If a TTY bolt was used in an older engine, using old, nonTTY torque specs, that bolt probably won’t stretch enough to provide the clamping force it’s capable of. The likely result is head gasket leaks. Likewise, if new TTY specs (involving both torque and bolt angle) are used on non-TTY bolts, chances are you’ll stretch these bolts beyond their elastic range, or break them, or damage the female threaded holes in the block. In short, TTY bolts are designed to stretch more, providing a long-term clamping load without the need to retorque. Most TTY cylinder head bolt specs will involve both an initial torque (in ft.lbs. or Nm), plus a specific degree of bolt head rotation, called torque plus angle tightening. Regardless of how silly the extra step of angle tightening may seem to some people, there’s a legitimate reason for this approach. Since bolt engineers already know how much stretch, and therefore clamping load, will occur based on how far a bolt head rotates, they use the angle of bolt head movement to determine exactly how much load is being exerted. A torque spec alone cannot be used to exactly determine bolt stretch because of the friction variables that come into play during tightening. A certain amount of torque loss is caused by the friction of the bolt head underside to the cylinder head contact surface, and by the friction of thread engagement. The type and amount of oil or lubricant on the threads provides 42 June 2009 yet another variable in terms of friction. Depending on how smooth and burrfree the bolt head contact area is, and on how smooth and uninterrupted the threads are on both the bolt and the female threaded hole, a torque reading alone really can’t provide accurate and consistent clamping load information. The resistance caused by bolt head or thread friction is read by a torque wrench in the same way bolt stretch is Top: This digital torque wrench display shows the selected torque value, in this case, in Nm. Center: With the press of a button, the window display quickly converts to ft.-lb. format. Above: For torque-angle applications, the display can show selected angle as well. Whenever the selected torque value or angle value is reached, the tool emits an audible signal. read—it’s all resistance to movement. If enough friction is created by these variables, a reading of 40 ft.-lbs. on a torque wrench may in reality provide the equivalent of only 20 ft.-lbs. that actually works to stretch the bolt. And if the bolt was designed to stretch to its justshort-of-yield point at a true 40 ft.-lbs., this inadequate bolt stretch will mean insufficient clamping load on the gasket. So, although some of us may not like to deal with TTY torque and angle specs, we really don’t have a choice. Should TTY Bolts Be Reused? This is an issue that will stir debate. A TTY bolt is designed to stretch to a point immediately prior to its yield point. On that basis, it’s theoretically possible to reuse them. Some carmakers claim it’s okay to reuse TTY bolts a specific number of times. However, that recommendation is based on the assumption that each bolt has been properly tightened in the past. Since you have no way of knowing whether a TTY bolt has been improperly tightened, perhaps past its yield, the safest course of action is to always use new TTY bolts in every single application. This recommendation is also made by the leading gasket makers, including Fel-Pro and Victor-Reinz. In fact, Fel-Pro has released a number of tech bulletins on this very subject, emphasizing the need to replace TTY bolts in every case (refer to Fel-Pro bulletins 4522-91, 4774-93, 4904S and 5052-96; and Perfect Circle’s Machine Shop Service Bulletin CH-7). Considering the cost of the bolts, it’s cheap insurance to protect a costly engine rebuild. When tightening a TTY bolt, you’ll invariably have to meet both torque and angle published specs. For instance, the spec may dictate that the bolt is torqued to 45 ft.-lbs., then tightened further by degrees of bolt head rotation (let’s say 45°). Some bolt specs may ask you to reach an initial torque, followed by several steps of rotation (20°, followed by 20°, followed by 10°, for example). To apply a specified torque, obviously you’ll need to use a torque wrench (needle type or click type). To tighten the bolt further by angle, you’ll need an angle meter. These are available as separate units that attach to the wrench. They feature indexable needles and provide a means of holding the meter base in position (so that only half the meter moves—either the needle or the meter scale). This hold-down may be in the form of a mechanical stop built into the meter or a remote cable secured to a convenient location on the cylinder head via a clamp or magnet. This article can be found online at www.motormagazine.com.