Tapered Pipe Thread Repair

The thread repair insert for tapered pipe threads is coated with a clear silver zinc coating.

Fig 1: Identifying Flange Of Insert And Surface Of Base Material Of Drilled/Tapped Hole

Courtesy of SUZUKI OF AMERICA CORP.

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.

Fig 2: Drilling Out Threads Of Damaged Hole

Courtesy of SUZUKI OF AMERICA CORP.

1. Drill out the threads of the damaged hole.
   Fig 3: Cleaning Out Chips From Drilled Hole Using Compressed Air

   Courtesy of SUZUKI OF AMERICA CORP.
   NOTE: All chips must be removed from the drilled hole prior to tapping.
2. Using compressed air, clean out any chips.
   Fig 4: Tapping Threads Of Drilled Hole

   Courtesy of SUZUKI OF AMERICA CORP.
   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.
3. Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.
   Fig 5: Tapping Drilled Hole Until Threads At Top Of Tap Are Down To Surface Of Base Material

   Courtesy of SUZUKI OF AMERICA CORP.
4. Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the base material.
   Fig 6: Cleaning Out Chips From Tapped Hole Using Compressed Air

   Courtesy of SUZUKI OF AMERICA CORP.
   NOTE: All chips must be removed from the tapped hole prior to insert installation.
5. Using compressed air, clean out any chips.
   Fig 7: Spraying Cleaner GM P/N 12346139, GM P/N 12377981 Into Tapped Hole

   Courtesy of SUZUKI OF AMERICA CORP.
6. 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

   Courtesy of SUZUKI OF AMERICA CORP.
   NOTE: All chips must be removed from the tapped hole prior to insert installation.
7. Using compressed air, clean out any chips.
   Fig 9: Lubricating Threads Of Driver Installation Tool With J 42385-110

   Courtesy of SUZUKI OF AMERICA CORP.
   NOTE: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
8. Lubricate the threads of the driver installation tool (2) with the J 42385-110 (1).
   Fig 10: Identifying Insert And Driver Installation Tool

   Courtesy of SUZUKI OF AMERICA CORP.
9. 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

   Courtesy of SUZUKI OF AMERICA CORP.
10. 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

    Courtesy of SUZUKI OF AMERICA CORP.
11. Install the insert (2) into the tapped hole by hand only.
    Fig 13: Identifying Flange Of Insert Contacts Surface Of Base Material

    Courtesy of SUZUKI OF AMERICA CORP.
    NOTE: If the insert will not thread down until the flange contacts the surface of the base material remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
12. Install the insert until the flange (2) of the insert contacts the surface of the base material.
    Fig 14: Identifying Driver Installation Tool, Top Of Threaded Section And Top Of Insert

    Courtesy of SUZUKI OF AMERICA CORP.
    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.
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).
    Fig 15: Inspecting Insert For Proper Installation Into Tapped Hole

    Courtesy of SUZUKI OF AMERICA CORP.
14. Inspect the insert (1) for proper installation (2) into the tapped hole.
    Fig 16: Identifying Oil Or Engine Coolant Passage

    Courtesy of SUZUKI OF AMERICA CORP.
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.