Stripped Banjo hole in head - how to stop leak?

[Crazy91GSX]

Hey guys, I have a problem with my 91 gsx. The the hole for the banjo bolt in the head stripped on me, so I ran the line to the oil filter housing. However, Since the hole is stripped, I can't completely tighten the banjo bolt, so oil will leak uner high pressure. I have tried to tap out the hole, but still won't tighten. Tried to completely fill the hole with quick steel, no go. Tried to tighten the bolt in as much as possible and then quick steel the outside of the hole, nothing. I don't know what to do anymore. But I have to get it fixed, because I cant run high pressure (boost) without leaking oil. Can I use silicone? Or another substance that will block the oil? Some other type of bolt? Anything!!

Thanks for any input,

Adam

 

[x camaro owner]

it doesn't matter what you use to try to fill it because the metal in the head will expand at a different rate than the material you will use to fill it so eventually it will leak again. do a better job on drilling and tapping it and use a screw. or you could try a helicoil either way drill it and tap is the correct way to fix the problem it can be done, maybe you should have some one else tap it maybe a machine shop, since you seem to be lacking in the tapping area. i am awesome at tapping sh*t

 

[4G63 GST]

same thing happened to me .. first tap it and just do the screw .. then if that doesnt work .. helicoil it for a plug .. cant reall do much else ..

Mine go all fixed though


Luke

 

[Twizzle]

well idk what these people are talking about but i took the easy route. i got an allen bolt plug that goes into the head, lubed it with a perfect mix of jbweld, tightened it in there, then jb welded around the bolt. havent had a leak since.

 

[91awd]

Does the bolt go in and out of the hole easily with the new threads? If so and it still leaks maybe you could try putting a crush washer on with the bolt. That's what we did on my friends car after he stripped it and it doesn't leak at all.

 

[1fast97gsx]

just take it to someone that can weld aluminum and weld the hole shut completely.

 

[JaxTalonTSi]

I had the same problem before. But the way the turbo line is going from the head to the turbo, you can't drill and tap the hole if that line is in the way, and you can't take that off without taking off the turbo.

So what I did was go to NAPA, and got the same size thread banjo bolt, but just a tiny bit longer. Problem was, the hollow part in the bolt and the holes were half the size of the one on the bolt that came off the car. So I just put the thing in a vice, got a drill and enlarged the holes. Then I got the bolt started in the head, and just tightened it up. NO MORE LEAKING OIL

I'm sure whenever I pull off the turbo again, I will fix this the "proper" way, but the longer fixed banjo bolt worked just fine.

 

[HondaStalker]

Try putting it on there without the washer, it might grab the last threads and tighten, my cousin just had this problem and he put it on w/o the washer and it got tight, napa sells a kit for this stuff(60 bucks)