Thread Repair
Thread Repair |
Special Tools
• |
EN 42385-700
High Feature Thread Repair Kit
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• |
EN 42385-2000
Thread Insert Kit
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• |
EN 43965
Thread Repair Extension Kit
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For equivalent regional tools, refer to Special Tools .
The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert. During the insert installation process, the installation driver tool cold-rolls the bottom internal threads and expands the bottom external threads of the insert into the base material. This action mechanically locks the insert into place.
It is critical that the drilling, counterboring and tapping of the hole to be repaired follows the same centerline as the original hole.
During the drilling and tapping of the hole being repaired ensure the tooling is consistently machining perpendicular to the surface of the base material.
If the threaded hole being repaired has a base surface perpendicular to the hole centerline, tapping guides are available to aid in tapping the hole.
Tap Size | Tap Guide | Tap Size | Tap Guide | Tap Size | Tap Guide |
- | EN 42385- | - | EN 42385- | - | EN 42385- |
6 x 1.0 | 729 | 10 x 1.5 | 731 | 14 x 1.5 | 736 |
8 x 1.25 | 730 | 12 x 1.5 | 732 | 20 x 1.5 | 737 |
Standard Thread Repair - Flush Hole |
Refer to Safety Glasses Warning .
Note | ||
The use of a cutting type fluid is recommended when performing the drilling, counterboring and tapping procedures. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended cutting fluid. |
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When installed to the proper depth, the flange (1) of the insert will be seated against the counterbore of the drilled/tapped hole and just below the surface (2) of the base material. |
1. |
Using compressed air, clean out any chips. |
2. |
Counterbore the drilled hole to the full depth permitted by the tool (1). |
3. |
Using compressed air, clean out any chips. |
4. |
Using a suitable tapping wrench, tap the threads of the drilled hole by hand only. Specifications
|
1. |
Using compressed air, clean out any chips. |
2. |
Spray cleaner into the tapped hole. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cleaner.
|
3. |
Using compressed air, clean out any chips. |
4. |
Lubricate the threads of the driver installation tool (2) with the EN 42385-110 (1). |
5. |
Install the insert (2) onto the driver installation tool (1).
|
6. |
Apply threadlock sealant, EN 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2). Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended sealant.
|
7. |
Install the insert (2) into the tapped hole by hand only.
|
8. |
Install the insert until the flange (2) of the insert contacts the counterbored surface. |
9. |
Continue to rotate the driver installation tool (1) through the insert (2). |
10. |
Inspect the insert for proper installation into the tapped hole. A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).
|
11. |
Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.
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Recessed Thread Repair |
Refer to Safety Glasses Warning .
Note | ||
• |
The use of a cutting type fluid, WD 40® or equivalent is recommended when performing the drilling, counterboring and tapping procedures. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cutting fluid.
|
|
• |
Do NOT remove the original stop collar from a counterbore drill.
|
When installed to the proper depth, the flange of the insert (1) will be seated against the counterbore (2) of the drilled/tapped hole.
1. |
Install a stop collar (2) on the counterbore drill (1), if required.
|
2. |
Drill out the threads of the damaged hole. |
3. |
Using compressed air, clean out any chips. |
4. |
Using a suitable tapping wrench, tap the threads of the drilled hole by hand only. |
5. |
Using compressed air, clean out any chips. |
6. |
Spray cleaner into the tapped hole. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cleaner.
|
7. |
Using compressed air, clean out any chips. |
8. |
Lubricate the threads of the driver installation tool (2) with the EN 42385-110 (1). |
9. |
Install the insert (2) onto the driver installation tool (1).
|
10. |
Apply threadlock sealant, EN 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2). Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended sealant.
|
11. |
Install the insert (2) into the tapped hole by hand only.
|
12. |
Install the insert until the flange (2) of the insert contacts the counterbored surface. |
13. |
Continue to rotate the driver installation tool (1) through the insert (2). |
14. |
Inspect the insert (1) for proper installation (2) into the tapped hole.
|
15. |
Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.
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Tapered Pipe Thread Repair |
The thread repair insert for tapered pipe threads is coated with a clear silver zinc coating.
Refer to Safety Glasses Warning .
Note | ||
The use of a cutting type fluid, WD 40® or equivalent is recommended when performing the drilling, counterboring and tapping procedures. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended cutting fluid. |
When installed to the proper depth, the flange (1) of the insert will be seated against surface (2) of the base material of the drilled/tapped hole.
1. |
Drill out the threads of the damaged hole. |
2. |
Using compressed air, clean out any chips. |
3. |
Using a suitable tapping wrench, tap the threads of the drilled hole by hand only. |
4. |
Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the base material.
|
5. |
Using compressed air, clean out any chips. |
6. |
Spray cleaner into the tapped hole. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cleaner.
|
7. |
Using compressed air, clean out any chips. |
8. |
Lubricate the threads of the driver installation tool (2) with the EN 42385-110 (1). |
9. |
Install the insert (2) onto the driver installation tool (1).
|
10. |
Apply threadlock sealant, EN 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2). Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended sealant.
|
11. |
Install the insert (2) into the tapped hole by hand only.
|
12. |
Install the insert until the flange of the insert (3) contacts the surface of the base material. |
13. |
Continue to rotate the driver installation tool (1) until the top of the threaded section (2) is level with the top of the insert (3). |
14. |
Inspect the insert (1) for proper installation (2) into the tapped hole.
|
15. |
Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or engine coolant passage drilled out (4) to the original size of the oil or engine coolant passage. After drilling the restriction or blockage, clean out any chips and thread the installation driver tool through the insert again to remove any burrs caused by the drilling of the oil or engine coolant passage.
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Cylinder Head Bolt Hole Thread Repair |
Special Tools
• |
EN 42385-700
High Feature Thread Repair Kit
|
• |
EN 42385-2000
Thread Insert Kit
|
For equivalent regional tools, refer to Special Tools .
Tools for repairing threaded bolt holes in the cylinder head are included in the insert kit EN 42385-2000 and the kit EN 42385-700 . Components for repairing threaded bolt holes in the cylinder head consist of:
• |
EN 42385-723 Drill (1)
|
• |
EN 42385-724 Tap (2)
|
• |
EN 42385-725 Installation driver (3)
|
• |
EN 42385-303 Alignment pin (4)
|
• |
EN 42385-302 Bushing (5)
|
• |
EN 42385-733 Bolts (6)
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• |
EN 42385-401 Fixture plate (7)
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Refer to Safety Glasses Warning .
Note | ||
• |
Remove the fixture plate prior to installing the insert with the installer tool.
|
|
• |
The use of a cutting type fluid, WD 40®; or equivalent is recommended when performing the drilling, counterboring and tapping procedures. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cutting fluid.
|
When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.
1. |
Position the fixture plate (3) with the bushing (1) installed over the cylinder head bolt hole to be repaired (4).
|
2. |
Loosely install the fixture plate bolts (2) into the remaining cylinder head bolt holes.
|
3. |
Position the alignment pin (1) through the bushing and into the cylinder head bolt hole.
|
4. |
With the alignment pin in the desired cylinder head bolt hole, tighten the fixture retaining bolts (2).
|
5. |
Remove the alignment pin (1) from the cylinder head bolt hole.
|
6. |
Drill out the threads of the damaged hole. |
7. |
Using compressed air, clean out any chips. |
8. |
Using a suitable tapping wrench, tap the threads of the drilled hole by hand only. |
9. |
In order to tap the new threads for the insert to the proper depth, rotate the tap into the cylinder head bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
|
10. |
Remove the fixture plate bolts (2). |
11. |
Remove the fixture plate (3) and bushing (1).
|
12. |
Using compressed air, clean out any chips. |
13. |
Spray cleaner into the tapped hole. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cleaner.
|
14. |
Using compressed air, clean out any chips. |
15. |
Lubricate the threads of the driver installation tool (2) with the EN 42385-110 (1). |
16. |
Install the insert (2) onto the driver installation tool (1).
|
17. |
Apply threadlock sealant, EN 42385-109, LOCTITE 277®; or equivalent (1) to the insert OD threads (2). Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended sealant.
|
18. |
Install the insert and installation driver (1) into the tapped hole by hand only.
|
19. |
Start the insert into the threaded hole.
|
20. |
Install the insert until the flange of the insert contacts the counterbored surface. |
21. |
Continue to rotate the driver installation tool through the insert. |
22. |
In order to completely form the new threads in the insert, rotate the driver installation tool through the insert until the mark (1) on the driver installation tool aligns with the surface of the engine block deck (2).
|
23. |
Inspect the insert for proper installation into the tapped hole.
|
Crankshaft Main Bolt Hole Thread Repair |
Special Tools
• |
EN 42385-700
High Feature Thread Repair Kit
|
• |
EN 42385-2000
Thread Insert Kit
|
For equivalent regional tools, refer to Special Tools .
Note | ||
• |
In order to repair some crankshaft main bolt holes it will be necessary to mount the fixture plate upside down.
|
|
• |
Do NOT remove the fixture plate prior to installing the insert with the installation driver. The fixture plate remains in position throughout the thread repair process.
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Tools for repairing threaded bolt holes in the crankshaft main bearing are included in the insert kit EN 42385-2000 and the kit EN 42385-700 . Components for repairing threaded bolt holes in the crankshaft main bearing consist of:
• |
EN 42385-702 Drill (1) for outboard holes
|
• |
EN 42385-703 Tap (2) for outboard holes
|
• |
EN 42385-704 Installation driver (3) for outboard holes
|
• |
EN 42385-726 Bushing (4) for outboard holes
|
• |
EN 42385-727 Alignment pin (5) for outboard holes
|
• |
EN 42385-728 Bolts (6) for outboard holes
|
• |
EN 42385-720 Drill (7) for inboard holes
|
• |
EN 42385-721 Tap (8) for inboard holes
|
• |
EN 42385-722 Installation driver (9) for inboard holes
|
• |
EN 42385-713 Bushing (10)
|
• |
EN 42385-308 Alignment pin (11)
|
• |
EN 42385-734 Bolts (12)
|
• |
EN 42385-712 Fixture plate (13)
|
Outboard Bolt Holes |
Refer to Safety Glasses Warning .
Note | ||
• |
Ensure the fixture plate is installed during the machining and installation processes of the insert.
|
|
• |
The use of a cutting type fluid, WD 40® or equivalent is recommended when performing the drilling, counterboring and tapping procedures. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cutting fluid.
|
When installed to the proper depth, the flange of the insert will be seated against the counterbore of the drilled/tapped hole.
1. |
Position the fixture plate (3) with the bushing (2) installed over the crankshaft main cap bolt hole to be repaired.
|
2. |
Loosely install the fixture plate bolts (1) into the remaining crankshaft main cap bolt holes.
|
3. |
Position the alignment pin (1) through the bushing and into the crankshaft main cap bolt hole.
|
4. |
With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixture retaining bolts (2).
|
5. |
Remove the alignment pin (1) from the crankshaft main cap bolt hole.
|
6. |
Drill out the threads of the damaged hole. |
7. |
Using compressed air, clean out any chips. |
8. |
Using a suitable tapping wrench, tap the threads of the drilled hole by hand only. |
9. |
In order to tap the new threads for the insert to the proper depth, rotate the tap into the crankshaft main cap bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
|
10. |
Using compressed air, clean out any chips. |
11. |
Spray cleaner into the tapped hole. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cleaner.
|
12. |
Using compressed air, clean out any chips. |
13. |
Lubricate the threads of the driver installation tool (2) with the EN 42385-110 (1). |
14. |
Install the insert (2) onto the driver installation tool (1).
|
15. |
Apply threadlock sealant, EN 42385-109, LOCTITE 277®, or equivalent (1) to the insert OD threads (2). Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended sealant.
|
16. |
Install the insert and installation driver into the tapped hole by hand only.
|
17. |
Start the insert into the threaded hole.
|
18. |
Install the insert until the flange of the insert contacts the counterbored surface. |
19. |
Continue to rotate the driver installation tool through the insert. |
20. |
Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with the top of the drill bushing (2).
|
21. |
Inspect the insert for proper installation into the tapped hole.
|
22. |
Remove the fixture plate bolts (1).
|
23. |
Remove the fixture plate (3) and bushing (2).
|
Inboard Bolt Holes |
1. |
Refer to
Safety Glasses Warning
.
Position the fixture plate (3) with the bushing (1) installed over the crankshaft main cap bolt hole to be repaired. |
2. |
Loosely install the fixture plate bolts (2) into the remaining crankshaft main cap bolt holes.
|
3. |
Position the alignment pin (1) through the bushing and into the crankshaft main cap bolt hole.
|
4. |
With the alignment pin in the desired crankshaft main cap bolt hole, tighten the fixture retaining bolts (2).
|
5. |
Remove the alignment pin (1) from the crankshaft main cap bolt hole.
|
6. |
Drill out the threads of the damaged hole. |
7. |
Using compressed air, clean out any chips. |
8. |
Using a suitable tapping wrench, tap the threads of the drilled hole by hand only. |
9. |
In order to tap the new threads for the insert to the proper depth, rotate the tap into the crankshaft main cap bolt hole until the mark (3) on the tap aligns with the top of the drill bushing (2).
|
10. |
Using compressed air, clean out any chips. |
11. |
Spray cleaner into the tapped hole. Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended cleaner.
|
12. |
Using compressed air, clean out any chips. |
13. |
Lubricate the threads of the driver installation tool (2) with the EN 42385-110 (1). |
14. |
Install the insert (2) onto the driver installation tool (1).
|
15. |
Apply threadlock sealant, EN 42385-109, LOCTITE 277®, or equivalent (1) to the insert OD threads (2). Refer to
Adhesives, Fluids, Lubricants, and Sealers
for recommended sealant.
|
16. |
Install the insert and installation driver into the tapped hole by hand only.
|
17. |
Start the insert into the threaded hole.
|
18. |
Install the insert until the flange of the insert contacts the counterbored surface. |
19. |
Continue to rotate the driver installation tool through the insert. |
20. |
Rotate the driver installation tool until the mark (3) on the driver installation tool aligns with the top of the drill bushing (2).
|
21. |
Inspect the insert for proper installation into the tapped hole.
|
22. |
Remove the fixture plate bolts (2).
|
23. |
Remove the fixture plate (3) and bushing (1).
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