Stripped alternator cover bolt holes

erkishhorde · April 15, 2009, 09:13:08 PM

So I finally got around to taking off the alternator cover to tighten up the starter motor mounting bolts that I suspect was causing a very small oil leak. But when bolting everything up I found a 4 bolts that had stripped holes.

2 of them I can get a longer screw to grab onto threads deeper inside the hole but the 4th (behind the clutch slave) can't be helped much. I got it just barely snug with a screwdriver and don't have to worry about it backing out since it's behind the slave. Hopefully it doesn't leak. I don't think it will.

Anyway, the longer bolts grabbing more thread in the other 3 bolts won't last long I'm thinking. Knowing me I'll likely strip them the next time I take them off. I can be a bit ham fisted sometimes.

Any suggestions on fixing these stripped holes so I know what to do when they finally give out?

Howie · April 15, 2009, 10:31:13 PM

Quote from: erkishhorde on April 15, 2009, 09:13:08 PM
So I finally got around to taking off the alternator cover to tighten up the starter motor mounting bolts that I suspect was causing a very small oil leak. But when bolting everything up I found a 4 bolts that had stripped holes. 2 of them I can get a longer screw to grab onto threads deeper inside the hole but the 4th (behind the clutch slave) can't be helped much. I got it just barely snug with a screwdriver and don't have to worry about it backing out since it's behind the slave. Hopefully it doesn't leak. I don't think it will.

Anyway, the longer bolts grabbing more thread in the other 3 bolts won't last long I'm thinking. Knowing me I'll likely strip them the next time I take them off. I can be a bit ham fisted sometimes. Any suggestions on fixing these stripped holes so I know what to do when they finally give out?

If the cover was off before the bolts may have been shuffled and some may not be long enough. I think the one behind the slave will be problematic since the slave tries to move that part, but you might be lucky. If it leaks there the leak should not be bad, though.

If there is enough meat around the affected holes these are the answer:
http://www.timesert.com

wiggy_nz · April 16, 2009, 01:06:41 AM

Heli Coil will do the trick. I have used them before on a Honda motor.
Brendan

amcloud · April 16, 2009, 06:19:17 AM

Quote from: wiggy_nz on April 16, 2009, 01:06:41 AM
Heli Coil will do the trick. I have used them before on a Honda motor.
Brendan

Don't use a helicoil. Use a time-sert. They are a much better solution, and if installed correctly, stronger than the original threads. Google them.

ducpainter · April 16, 2009, 06:25:07 AM

Quote from: amcloud on April 16, 2009, 06:19:17 AM
Don't use a helicoil. Use a time-sert. They are a much better solution, and if installed correctly, stronger than the original threads. Google them.

Time sert is a great product, but for this application I think I'd use a helicoil too.

We're talking about a 6 mm screw, not a spark plug or cylinder stud.

ducatiz · April 16, 2009, 06:28:37 AM

Quote from: ducpainter on April 16, 2009, 06:25:07 AM
Time sert is a great product, but for this application I think I'd use a helicoil too.

We're talking about a 6 mm screw, not a spark plug or cylinder stud.

+1, cheaper too

those screws are not under a lot of torque, just a bit

brad black · April 16, 2009, 06:35:03 AM

the one behind the slave is the most important as the slave is trying to pull the cover off the cases every time you pull the clutch in.

the helicoil kit is expensive if you have only 1 to do, but if you're doing 4 it's not so bad and they're mighty useful. make sure you get the right size drill too and use some crc, wd40 or the like when drilling and tapping the thread.

Speeddog · April 16, 2009, 09:55:38 AM

TimeSert +1

Helicoil -1

erkishhorde · April 16, 2009, 10:22:29 AM

Heh, the Helicoil site likes to flash around that it's a US product but payment options are in USD or Indian Rupees...

I think I'll be researching this a bit. I've got some time... I think. I don't plan on fixing it just yet.

Duck-Stew · April 16, 2009, 10:28:51 AM

TIME-SERT.

Heli-coil ******only****** if you have to. Nevermind the bolt size/thread/torque value.

This is my opinion, YMMV.

Langanobob · April 16, 2009, 10:40:16 AM

I *think* Heli-coils may use a slightly smaller drill bit and tap. If that's true, then I'd go with Heli-coil since there isn't a lot of extra meat in the threaded area. Properly installed, they are going to work just fine. But if the tap size is the same, either method will work fine.

I think that just like the global warming issue, this one is split right down political lines. Everyone who insists Time-Serts for this one voted for McCain and Heli-Coilers went with Michelle's husband. See - if you don't agree with me on Heli-coils for this particular application I'll just get this thread locked.

Speeddog · April 16, 2009, 11:42:15 AM

TimeSerts take smaller drills and taps than Helicoils.

erkishhorde · April 16, 2009, 11:44:24 AM

Lol, the timesert instructional video has a sales pitch at the end that says they have inserts with thicker walls in case you need to fix a helicoil that failed.

Speeddog · April 16, 2009, 11:49:57 AM

I've got the whole kit, and inserts too.

erkishhorde · April 16, 2009, 11:52:58 AM

Hmmm... This kind of repair is most likely done with the cover off, yes? Me thinks Nick will be seeing me the next time I need an oil change. Hmmm... I should note which ones are damaged now before I forget. As it is I can only remember 3 of them... Coulda sworn there was a 4th...

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Stripped alternator cover bolt holes