Recessed Thread Repair

WARNING: This page is about a different car, the 2008 Suzuki XL7. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Inspecting Flange Of Insert Will Be Seated Against Counterbore Of Drilled/Tapped Hole

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WARNING: Refer to SAFETY GLASSES CAUTION .

NOTE:

The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40® or equivalent is recommended when performing the drilling, counterboring and tapping procedures.
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.

Fig 2: Identifying Stop Collar And Counterbore Drill

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Install a stop collar (2) on the counterbore drill (1), if required.

Fig 3: Drilling Out Threads Of Damaged Hole
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NOTE:
- During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.
- Drill the hole until the stop collar contacts the surface of the base material.
Drill out the threads of the damaged hole.

Fig 4: Cleaning Out Chips From Drilled Hole Using Compressed Air
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NOTE: All chips must be removed from the drilled hole prior to tapping.
Using compressed air, clean out any chips.

Fig 5: Tapping Threads Of Drilled Hole Using Suitable Tapping Wrench
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NOTE:
- During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.
- Ensure the tap has created full threads at least to the depth equal to the insert length.
Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.

Fig 6: Cleaning Out Chips From Tapped Hole Using Compressed Air
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NOTE: All chips must be removed from the tapped hole prior to insert installation.
Using compressed air, clean out any chips.

Fig 7: Spraying Cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) Into Tapped Hole
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Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.

Fig 8: Cleaning Out Chips From Tapped Hole Using Compressed Air
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NOTE: All chips must be removed from the tapped hole prior to insert installation.
Using compressed air, clean out any chips.

Fig 9: Lubricating Threads Of Driver Installation Tool With J 42385-110
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NOTE: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
Lubricate the threads of the driver installation tool (2) with the J 42385-110 (1).

Fig 10: Identifying Insert And Driver Installation Tool
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Install the insert (2) onto the driver installation tool (1).

Fig 11: Applying Threadlock Sealant GM P/N 12345493, LOCTITE 277® To Insert OD Threads
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Apply threadlock sealant GM P/N 12345493, (Canadian P/N 10953488), J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).

Fig 12: Identifying Insert And Tapped Hole
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Install the insert (2) into the tapped hole by hand only.

Fig 13: Identifying Flange Of Insert Contacts Counterbored Surface
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NOTE: If the insert will not thread down until the flange contacts the counterbored surface remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
Install the insert until the flange (2) of the insert contacts the counterbored surface.

Fig 14: Identifying Driver Installation Tool And Insert
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NOTE: The driver installation tool will tighten up before screwing completely through the insert. This is acceptable. The threads at the bottom of the insert are being formed and the insert is mechanically locking the insert into the base material threads.
Continue to rotate the driver installation tool (1) through the insert (2).

Fig 15: Inspecting Insert For Proper Installation Into Tapped Hole
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Inspect the insert (1) for proper installation (2) into the tapped hole.

Fig 16: Identifying Oil Or Engine Coolant Passage
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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.