Still waiting for ONE example of where reusing the bolts have caused any issue. Nothing yet??? :rofl:

Was there a bolt failure that actually broke a bolt loosening the plate or was it improper tightening? The most likely cause was "operator error".

Just because it doesn't break, doesn't mean it was installed properly.

The purpose of the plate is for chassis stiffness. Clamping force AKA friction is what keeps the plate from rotating and flexing and adds rigidity. You're not likely to break a bolt unless it was continuously yielded each time it was retorqued.

One of the ways out is to increase the grade of the bolt and increase the clamping torque to be equivalent with the TTY fastener.

There have been members in the NE US (NY if I recall correctly), that reported "clunking" from the front suspension after reusing the TTY plate fasteners. This was around 2 yrs ago.

The final solution to the issue was new TTY bolts & nuts.

The swaybar bushing mounts were not secured properly due to first stage torquing (40 ft/lbs), was actually being reached forcing the nut onto the deformed bolt thread. The following 90 deg (2nd stage) was actually leaving the bushing mounts loose.

Mine is a 4.4 production date: March 2004. Aluminum plate. Re-used the bolts with "0" issues. Before re-using the bolts, I measured the threads of the bolts from the outer edge to the base with a vernier caliper. I haven't spotted a difference in OD, that's why I re-used them. On the other hand, I haven't measured the nuts (the ID). Maybe those get deformed when tightening? I dunno, they "felt" like any other "regular" nut used on these cars, where you can thread it by hand, then it won't go in any further until one uses a wrench.
Maybe it's a wrong approach, but if I would have spotted the smallest difference in OD of the threaded part of the bolt, for sure I would have purchased and used a new set of bolts.

I wasn't aware that metallurgical changes were visible to the naked eye. You learn something every day on this board...

On a stretch bolt I believe you can measure the difference in OD, pending on the thickness of the bolt. Vernier caliper is not naked eye. Mine has digital reading and 3 digits after the comma. Not sure where the naked eye is coming in.
But more powah to you bro'.

Okay, so "you believe" you can measure the difference. Do you KNOW this is fact? Are the stiffening plate bolts ACTUALLY stretch bolts, or do they undergo a metallurgical change which is NOT visible to the naked eye, or measurable by vernier calipers.

And yeah, I'm aware of some of these things having been a qualified mechanic for over 25 years. But as you said, "more powah to you bro".

FYI - vernier calipers are a decidedly unreliable way to measure the OD of a bolt, as the measuring face is very slim compared to the shaft of the bolt. It is notoriously easy to measure at an angle which is not totally perpendicular to the shaft of the bolt, resulting in a measurement which is imprecise. But I guess you knew all that. I guess you also measured the diameter of the bolt before you fitted it, and that the measurements were undertaken in similar atmospheric conditions, with the bolts at stable temperatures. All these things affecting your "3 digit accuracy". But again, guessing you knew all that...