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Replacing washer springs is a common maintenance task in both industrial and DIY settings. Whether you are working on machinery, vehicles, or home appliances, understanding how to replace washer springs correctly ensures that Bolts and nuts remain tight, prevents loosening, and extends the lifespan of your equipment. In this guide, we will cover the differences between Spring washers and lock washers, discuss various types like tapered Spring Washers, split washer and Flat washer combinations, and provide step-by-step replacement instructions. We’ll also reference common sizes such as M2 spring washer, M2.5 spring washer, and sourcing options like spring washer Bunnings or professional spring washer suppliers.
What Is a Spring Washer and How It Works
A spring washer is not just a regular washer. Unlike a flat washer, which only distributes load, a spring washer applies continuous tension, helping maintain bolt torque and resist loosening due to vibration or dynamic loads.
Spring washers work by folding slightly under compression, allowing the washer to rotate or turn as needed during tightening. This action provides automatic closure over minor gaps in the assembly, ensuring that the clamping force is maintained over time. The functionality of a spring washer makes it particularly effective in mechanical shafts where the washer generates torque and significantly impacts the service life of the assembly.
Key specifications to consider when replacing washer springs include:
Outer Diameter (OD): 1.7–28 mm
Inner Diameter (ID): 0.83–20.5 mm
Thickness: 0.15–2.0 mm
Material: 65Mn / SK5 / SK7
HRC: 43–50
Surface Treatment: Eco-friendly nickel, electroless nickel, blackening, zinc-nickel alloy
These parameters are crucial for ensuring proper fit, tension, and durability.
Spring Washer vs Lock Washer
A common question is: is a spring washer the same as a lock washer? The answer is nuanced.
A spring washer is a type of lock washer designed specifically to maintain tension through its curved or conical shape.
Other lock washers, such as split washers or toothed washers, may prevent rotation mechanically rather than through spring tension.
When replacing washers, understanding this distinction ensures you choose the correct part for your assembly.
Types of Washer Springs
1. Split Washer and Flat Washer
Many assemblies combine a split washer and flat washer. The flat washer provides a smooth surface to protect the material beneath the bolt, while the split washer acts as a spring to maintain tension.
2. Tapered Spring Washers
Tapered spring washers are conical and are often used in automotive and industrial machinery. They compress under load, generating axial tension that maintains bolt torque. Correct orientation during installation is critical—typically, the narrow side faces the bolt head, allowing proper compression.
3. Standard Spring Washers
Common standard spring washers include M2 spring washer, M2.5 spring washer, and larger sizes. These washers are suitable for light to medium-duty applications, electronics, and small mechanical assemblies.
Step-by-Step: How to Replace Washer Springs
Step 1: Identify the Washer
First, measure the outer diameter, inner diameter, and thickness of the existing washer. Note the material (65Mn, SK5, SK7) and surface treatment if possible. This ensures that your replacement will fit correctly and maintain proper torque.
Step 2: Remove the Fastener
Loosen the nut or bolt that holds the washer in place. For tight or corroded fasteners, apply a small amount of lubricant.
Step 3: Remove the Old Washer
Take out the old spring washer. If it’s a tapered spring washer, note its orientation—the narrow side should typically face the bolt head. Inspect the assembly for wear or damage.
Step 4: Install the New Washer
Place the new washer in the same orientation as the old one. If combining a split washer and flat washer, the flat washer goes on first, followed by the spring washer. This ensures the washer can fold, rotate, and turn properly under compression, achieving automatic closure of any minor gaps.
Step 5: Reassemble and Tighten
Install the nut or bolt and tighten to the recommended torque. Observe the washer as it compresses, ensuring it maintains spring tension without being over-flattened.
Step 6: Test the Assembly
After replacement, check that the assembly remains secure under vibration or slight movement. A properly installed spring washer will resist loosening while allowing minimal rotation and turning, maintaining clamping force.
Common Sizes and Applications
M2 spring washer / M2.5 spring washer: Small assemblies, electronics, light machinery
Tapered spring washers: Automotive components, industrial machinery, high-torque shafts
10mm, 12mm, 16mm spring washers: Medium to heavy-duty machinery
Split washer and flat washer combinations: Furniture, mechanical assemblies, DIY projects
Small spring washers: Compact applications where space is limited
The right size ensures the washer will generate sufficient torque and maintain service life of the assembly.
Sourcing Washer Springs
You can source replacement washers through:
Spring washer Bunnings – Ideal for home DIY and small projects
Spring washer suppliers – For industrial-grade or custom specifications, including tapered spring washers or specialty materials
When purchasing, verify OD, ID, thickness, material, HRC, and surface treatment to ensure compatibility.
Tips for Replacing Washer Springs
Do not reuse deformed washers – Flattened or worn washers will not provide proper tension.
Check torque specifications – Over-tightening can flatten the washer excessively.
Use the correct orientation for tapered washers – Improper orientation reduces effectiveness.
Combine with flat washers if needed – Protects the assembly and improves load distribution.
Choose the right material – High-strength alloys such as 65Mn or SK7 provide durability and maintain torque over time.
Conclusion
Replacing washer springs is essential for maintaining bolt tension and preventing loosening in assemblies. Correct replacement involves identifying the type of washer—whether a spring washer, tapered spring washer, or split washer and flat washer combination—removing the old washer, installing the new one in the proper orientation, and tightening to the recommended torque.
Common sizes, from M2 spring washer and M2.5 spring washer to 10mm, 12mm, and 16mm spring washers, ensure that you can find the right component for any application. Sourcing through spring washer Bunnings or professional spring washer suppliers guarantees quality, material compatibility, and durability.
Proper installation ensures that the washer will fold, rotate, turn, and automatically close gaps as needed, generating torque within the shaft and significantly impacting service life. Following these guidelines will help your mechanical assemblies remain secure, stable, and long-lasting.
