Cylinder Head Bolt Hole Thread Repair

Cylinder Head Bolt Hole Thread Repair

^ Tools Required
- J 42385-2000 Thread Insert Kit





The cylinder head bolt hole thread repair kit J42385-2000 components consist of the following:
^ Drill (1) J 42385-2006
^ Tap (2) J 42385-2007
^ Installation driver (3) J 42385-2008
^ Stop collar (4) for inboard holes J 42385-2017
^ Alignment pin (5) J 42385-303
^ Bushing (6) J 42385-302
^ Bolts (7) J 42385-503 & 604
^ Fixture plate (8) J 42385-301

Inboard Bolt Holes

Caution: Refer to Safety Glasses Caution in Service Precautions.

Important:
^ Remove the fixture plate prior to installing the insert with the installer tool.
^ The use of a cutting type fluid GM P/N US 1052864, Canada 992881, WD 400D or equivalent is recommended when performing the drilling, counterboring and tapping procedures.

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. Install the stop collar (2) onto the drill (1).





Important:
^ 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 top of the drill bushing.

7. Drill out the threads of the damaged hole.





Important: All chips must be removed from the drilled hole prior to tapping.

8. Using compressed air, clean out any chips.





Important:
^ 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.

9. Using a suitable tapping wrench, tap the threads of the drilled hole.





10. 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 first mark (1) on the tap aligns with the top of the drill bushing (3).





Important: Remove the fixture plate prior to installing the insert with the installer tool.

11. Remove the fixture plate bolts (2).
12. Remove the fixture plate (3) and bushing (1).





Important: All chips must be removed from the tapped hole prior to insert installation.

13. Using compressed air, clean out any chips.





14. Spray cleaner GM P/N 12346139, P/N 12377981 or equivalent into the tapped hole.





Important: All chips must be removed from the tapped hole prior to insert installation.

15. Using compressed air, clean out any chips.





Important: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.

16. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.





17. Install the insert (2) onto the driver installation tool (1).





18. Apply threadlock sealant GM P/N US 12345493, Canada 10953488, J 42385-109, LOCTITE 277, or equivalent (1) to the insert OD threads (2).





19. Install the insert and installation driver (1) into the tapped hole.
20. Start the insert into the threaded hole.

Important: 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.

21. Install the insert until the flange of the insert contacts the counterbored surface.

Important: 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.

22. Continue to rotate the driver installation tool through the insert.
23. Inspect the insert for proper installation into the tapped hole.

Outboard Bolt Holes

Caution: Refer to Safety Glasses Caution in Service Precautions.

Important:
^ Remove the fixture plate prior to installing the insert with the installer tool.
^ The use of a cutting type fluid GM P/N US 1052864, Canada 992881, WD 40 or equivalent is recommended when performing the drilling, counterboring and tapping procedures.

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 cylinder head bolt hole to be repaired (4).
2. Loosely install the fixture plate bolts (1) 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.





Important:
^ 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 top of the drill bushing.

6. Drill out the threads of the damaged hole.





Important: All chips must be removed from the drilled hole prior to tapping.

7. Using compressed air, clean out any chips.





Important:
^ 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.

8. Using a suitable tapping wrench, tap the threads of the drilled hole.





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 second mark (1) on the tap aligns with the top of the drill bushing (3).





Important: Remove the fixture plate prior to installing the insert with the installer tool.

10. Remove the fixture plate bolts (1).
11. Remove the fixture plate (3) and bushing (1).





Important: All chips must be removed from the tapped hole prior to insert installation.

12. Using compressed air, clean out any chips.





13. Spray cleaner GM P/N 12346139, P/N 12377981 or equivalent into the tapped hole.





Important: All chips must be removed from the tapped hole prior to insert installation.

14. Using compressed air, clean out any chips.





Important: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.

15. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.





16. Install the insert (2) onto the driver installation tool (1).





17. Apply threadlock sealant GM P/N US 12345493 Canada 10953488, J 42385-109, LOCTITE 277 or equivalent (1) to the insert OD threads (2).





18. Install the insert and installation driver (1) into the tapped hole.
19. Start the insert into the threaded hole.

Important: 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.

20. Install the insert until the flange of the insert contacts the counterbored surface.

Important: 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.

21. Continue to rotate the driver installation tool through the insert.
22. Inspect the insert for proper installation into the 8 tapped hole.