My DIY wheel bearing replacement ('01 A6) has had its share of challenges (pinch bolt, TRE fused etc).

My final step was to drill out the track rod end pinch bolt (fused in housing). Several bits later and a lot of patience, I thought I made real progress until I realised I had drilled off centre into the softer aluminum. So hadn't removed the part of the bolt that 'pinches'; once I drifted that out, I now have two concentric 10mm holes.

Image here: TRE pinch | Flickr - Photo Sharing!

Net result, bolt is loose and won't hold the TRE in place unless I wedge it. I could try and bore it out to 12mm but not that confident I'll get it right.

Obviously concerned as it's a steering component - is this worth taking a risk on or should I just replace the whole lot?

 

Personally, I wouldn't make the hole larger, as there will be less metal around the edges.