Notes

Penny Washer = Extra Large Diameter washer with stated bolt diameter hole.
Setscrew = Fully threaded from under head to end.
Bolt = Part plain shaft part threaded. Must be used where radial loads exist (e.g. Suspension Bushes).
All bolt lengths are measured from under the head to the end.

http://www.namrick.co.uk/ - a good but not especially cheap source of imperial and metric bolts, but not the trailing arm pivot bolts, for those use Steve Heath below.
http://www.shengltd.com/catalog/ - Steve does a suspension bolt kit which does take some of the pain away.
http://www.boltmeup.com good stainless range
ebay seller - jez1964 - certainly good for V8 engine bolts as I (Barkychoc) have used them on my engine.

Note - the S4 has a V8S chassis - so where it refers to V8 this may also apply to the S4.

As with anything TVR there may be variations!

Acknowledgement to Ken (Spludge) for producing the original excel list which this is based on.

Barkychoc

Bolt List

Description	Qty	Size	Length	Type	Nut	Washer	Washer	Remarks
Front Suspension
Upper Wishbone - Chassis	4	1/2" UNF	3"	Bolt	Nyloc	Plain	Plain
Lower Wishbone - Chassis	4	1/2" UNF	3"	Bolt	Nyloc	Plain	Plain
Shock Absorber	4	1/2" UNF	3"	Bolt	Nyloc	Plain	Plain
Upper Wishbone - Balljoint	4	7/16" UNF	3"	Bolt	Nyloc	Plain	Plain
Lower Wishbone - Balljoint	4	M8	45mm	Bolt	Nyloc	Plain	Plain
Lower Wishbone - Balljoint	2	M8	25mm	Bolt / Setscrew	Nyloc	Plain	Plain
ARB Clamp	4	M10	35mm	Setscrew	Nyloc	Plain	Plain
ARB Droplink	2	M10x1.0	x	x	Nyloc	Plain	x
Track Rod	2	M14	x	x	Plain	x	x
Track Rod End	2	7/16" UNF	x	x	Nyloc	Plain	x
Front Hub Pinch Bolt	2	M12	70mm	Setscrew	Nyloc	Plain	x	Torque setting 77 - 92 Nm or 57 - 68 lb ft
Steering
Steering Rack Clamp	4	M8	25mm	Setscrew	x	Plain	Spring
Steering UJ Lower	2	M8	35mm	Setscrew	Nyloc	x	x	Note Rally Design Forged UJ needs 40mm bolts
Steering UJ Upper	1	M8	35mm	Setscrew	Nyloc	x	x
Steering UJ Upper	1	M8	x	x	x	x	x	Tri-lobe Thread Forming
Steering Bulkhead Bearing Original Plastic	5	M5	25mm	Setscrew	Nyloc	Plain	Plain
Steering Bulkhead Bearing TVRCarparts Metal Type	5	M5	35mm	Setscrew	Nyloc	Plain	Plain	Allen head bolts not essential but make life easier
Chassis Front
V6 Swirl Pot - Chassis	3	M6	20mm	Setcrew	Nyloc	Plain	Plain
V6 Swirl Pot - Chassis	1	M6	25mm	Setcrew	Nyloc	Plain	Plain	Battery Tray
V8 Swirl Pot - Chassis	2	M6	20mm	Setcrew	Nyloc	Plain	Plain
V8 Swirl Pot - Chassis	2	M6	x	x	Nyloc	Plain	x	Studs on chassis
V6 Battery Tray - Chassis	1	M6	20mm	Setcrew	Nyloc	Plain	Plain	Not V8
V6 Battery Clamp	2	M6	25mm	Setcrew	Nyloc	Plain	Plain	Not V8
Radiator Frame - Chassis	4	M6	20mm	Setcrew	Nyloc	Plain	Plain
Chassis Earth	3	M8	x	x	Nyloc	Plain	Plain
Servo - Master Cylinder	2	M10	x	x	Nyloc	Plain	x
Servo - Pedal box/body	4	M8	x	x	Nyloc	Plain	x
Brake Valve Bracket to body	3	M5	20mm	Setscrew	Nyloc	Plain	Plain	Later type L shaped bracket
Brake Valve - Bracket	1	M10	70mm	Setscrew	Nyloc	Plain	Plain	Later type L shaped bracket
V8 Removeable chassis member	4	M10	70mm	Bolt / Setscrew	Nyloc	Plain	Plain
Front calliper - front hub	4	M10	25mm	Setcrew	x	x	x	10.9 Strength setscrew. Blue threadlock required.
V8 Air intake support pipe	1	M8	x	x	Nyloc	Plain	x
V8 Air intake support pipe	1	M8	x	x	Plain	Spring	Plain
V8 Exhaust manifold bolts	16	3/8" UNC	1"	Setscrew	Spring	x	x	STAINLESS STEEL PREF or better use ARP bolt kit
V8 Exhaust 'Y' piece - manifolds pre cat	6	M8	40mm	Bolt / Setscrew	Spring	Spring	Plain	STAINLESS STEEL PREFERRED
V8 Engine Mount - Chassis	4	M10	35mm	Setscrew	Nyloc	Plain	Plain
Chassis - Bonnet hinge	2	M12	15mm*	Setscrew	x	Plain	Spring	*Saw off to 15mm long if unavailable
Chassis Rear
Tank Cradle - Chassis	2	M10	30mm	Setscrew	x	Plain	Spring	Use allen head bolt if space tight for hex socket
Tank Cradle - Chassis	2	M10	30mm	Setscrew	Nyloc	Plain	Plain
Tank Strap	4	M8	20mm	Setscrew	Nyloc	Plain	Plain
V6 Exhaust - Tank Cradle	1	M10	70mm	Setscrew	x	Plain	Spring	(Not V8) Additional washers for packing
V8 Exhaust - centre mount	2	M10	70mm	Bolt / Setscrew	Nyloc	Penny	Penny	Setscrew
V8 Exhaust - rear hanger	1	M6 Stud	x	x	Nyloc	Plain	x	M6 Stud bent at 90 degrees
V8 Exhaust - rear mount	2	M6	x	x	Nyloc	Plain	x
V8 Fuel Pump bracket pinch bolt	1	M8	45mm	Bolt / Setscrew	Nyloc	Plain	Plain
V8 Fuel Filter bracket pinch bolt	1	M8	45mm	Bolt / Setscrew	Nyloc	Plain	Plain
V6 Fuel Pump bracket pinch bolts	2	M6	20mm	Setscrew	Nyloc	Plain	Plain
V6 Fuel Filter bracket pinch bolt	1	M8	35mm	Bolt	Nyloc	Plain	Plain	Thread Length = 25mm
V8 (rear disc brake) hub housing - trailing arm	8	M10	40mm	Setscrew	x	Spring	x
V8 rear brake calliper - rear hub housing	4	M10	40mm	Setscrew	x	Plain	x	10.9 Strength setscrew. Blue threadlock required.
V6 Hub housing - trailing arm (rear drum brake)	8	M10	35mm	Setscrew	x	Spring	x	8.8 strength, 4 per side
V6 Brake cylinder retaining bolts (rear drum brake)	4	M6	12mm	Bolt	x	Spring	x	2 bolts per cylinder
Body
Body - Chassis (Boot)	2	M10	50mm	Setscrew	Nyloc	Penny	Penny	1 in fuel pump cavity on V8
Body - Chassis (Front Footwell)	4	M10	40mm	Setscrew	Nyloc	Penny	Penny
Body - Chassis (Inner)	2	M10	45mm	Setscrew	Nyloc	Penny	Penny
Body - Chassis (Seatbelt)	2	M12	50mm	Setscrew	x	Penny	x	Below seatbelt reel
Body - Chassis (Tunnel)	2	M10	25mm	Setscrew	x	Penny	Spring	Under centre console
Seatbelt
Seatbelt (Top)	2	7/16" UNF	1 1/4"	Bolt	x	x	x
Seatbelt (Outer)	2	7/16" UNF	1 1/4"	Bolt	x	x	x
Seatbelt (Inner)	2	7/16" UNF	1 1/2"	Bolt	x	x	x
Seatbelt (Reel)	2	7/16" UNF	1 1/4"	Bolt	Nyloc	Penny	Penny
Rear Suspension
Shock Absorber Top	2	1/2" UNF	2 1/2"	Bolt	Nyloc	Plain	Plain	Low Profile Nyloc (1/2" High), thin washers
Shock Absorber Bottom	2	1/2" UNF	2 3/4"	Bolt	Nyloc	Plain	Plain	Full Height Nyloc, 3" bolt ok
Trailing Arm Pivot	4	9/16" UNF	4 1/4"	Bolt	Nyloc	Plain	Plain	Steve Heath now supplies 4 1/2" bolts, rather than the 5" bolts which sometimes needed cutting down
2 part trailing arm joint bolts	8	3/8" UNF	1 3/16"	Setscrew	x	Spring	x
V8 Gearbox
V8 Rear gearbox Mount - body	2	1/2" UNC	3 1/2"	Bolt	Nyloc	Plain	Plain
V8 Rear gearbox Mount - gearbox	4	5/16" UNC	1"	Setscrew	x	Plain	Spring
V8 Rear gearbox Mount - centre bolt	1	1/2" UNF	3"	Bolt	Nyloc	Plain	Plain	Same as front wishbone bolt
V8 Bell Housing - Engine	6	3/8" UNC	2"	Bolt	x	Spring	x
V8 Bell Housing - Engine	2	3/8" UNC	2.5"	Bolt	x	Spring	x
V8 Front gearbox prop flange bolts	4	3/8" UNF	1.5"	Bolt*	Nyloc	Plain	Plain	*5/16" plain shaft then thread poss special rover bolt"
V8 Gear Knob	-	5/16" UNF	x	x	x	x	x
Diff
Diff side to diff carrier bolts	3	M12	50mm	Bolt	x	Plain	Spring	V6 (80-100 Nm Torque) & V8
Diff side to diff carrier bolts	1	M12	45mm	Bolt	x	smaller 24 dia	Spring	V6 & V8, OSF bolt shorter as carrier is recessed so head is flush (80-100 Nm Torque)
V8 Rear Diff carrier top rubber mounts(2) - chassis	2	M12	65mm	Setscrew	x	Spring	Penny	Taken from V8, V6 presumed same
V6 & V8 Rear prop flange bolts	4	M10 x 1.0	18mm	Bolt*	x	x	x	*Blue Threadlock 60Nm Torque
V8 Diff centre top bolts to rear mounting plate	2	M10	30mm	Setscrew	x	Plain	Spring	V8 Specific, V6 different
V6 Diff centre top bolts to rear mounting plate	2	M10	30mm	Setscrew	x	Plain	x	V6 Specific, V8 different (45 Nm Torque)
V8 diff rear outer top bolts - rear mounting plate	4	M10	70mm	Bolt Allen Head	x	Spring	x	Allen heads not hex. V8 Specific
V8 Diff rear mounting plate to chassis	2	1/2" UNF	2 1/2"	Bolt	Half Height Nyloc	Plain	Plain	V8 Specific, V6 different
V6 Diff rear mounting plate to chassis	4	M10	25 mm	Screw	Nyloc	Plain	Plain	V6 specific 60 Nm Torque
V6 CV Joint Torx screws	12	M8	50 mm	Screw	x	x	x	T45 finis code 6769287 30 Nm Torque

Torque Wrench Settings

Component	ft lbs	Nm
Caliper to upright	43-44	58-60
Rear brake carrier plate to axle HSG	45-48	61-65
Track rod end to upright	30-35	40-47
Bottom ball joint to upright	60-65	81-88
Top ball joint to upright	60-65	81-88
Upper ball joint adapter pinch bolt	59-66	80-89
Upper wishbone to ball joint HSG	35-40	47-54
Bottom wishbone to ball joint HSG	12-15	16-20
Steering rack mountings	12+90'	16+90'
Steering UJ clamp bolts	12-15	16-20
Front & rear hub retaining nuts make sure you turn it the right way! LH & RH Threads	202-232	274-315
Rear caliper to bearing carrier	40-45	54-61
Rear bearing carrier to upright	45-48	61-65
Differential cross-member to diff casing	51-66	69-89
Differential cross-member to chassis	35-37	47-50
Rear diff mounting bolts to chassis	33-38	45-52
Rear diff mounting bolts to diff	33-38	45-52
Prop shaft to diff flange	39-42	53-57
Roll bar mounting bolt to chassis	35-40	47-54
Drive-shaft Torx bolts to diff	48-50	65-68
Drive-shaft Torx bolts to axle shafts	48-50	65-68
Upper and lower wishbones to chassis	59-65	80-88
TRG. arm toe adjuster to TRG. arm	25-30	34-41
Trailing arm to chassis	80-85	108-115
All damper bolts	58-60	79-81
Roll bar mounting clamp to chassis	30-35	40-47
Drive shaft bolts to diff	32-35	38-40
Drive shaft bolts to axle shafts	32-35	38-40
Seat belt anchorage bolts	25-30	34-41
Wheel nuts	73-77	99-104
Brake master cyl to servo	15-20	20-27
Gearbox cross member	45-50	61-68
Oil filler plug	25-33	34-45
Steering wheel nut	25-30	34-41
Clutch cover plate bolts	13-16	17-21