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Helicoil these threads?

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er82

Proven Member
243
28
Apr 18, 2014
Sacramento, California
Looks like someone tried to fix the threads, but failed. They are for the intermediate shaft bracket. Can these threads be fixed with something like helicoil? Is this something that a machine shop should do?

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Sure can. You can fix em with helicoils. Problem is, you dont know if they fixed them with the proper thread, which is 10 x 1.25, or sometging else. Get a 10 x 1.25 helicoil kit, pull those messed up coils out, then try running the supplied tap through the threads to see if theyre right and if so, run new coils in. If you take your time and do it right, helicoils are just fine for that sort of thing. Looking at that picture, im not sure if they even drilled out the old threads. As a caution, id get the specified drill bit which is 25/64, run it through after pulling those messed up coils out, then run the tap in and then your coils.
 
Also you can cut off a coil or two with a cut off wheel if you need to so the coil will go 1/2 a turn below the surface in a shallow hole.

Looks like they tried to fix it, but the coils were longer than the hole was deep.
 
Just an update. I took the block to 3 different machine shops and all said that holes were drilled too big. So it cannot be fixed. They didn't want to weld it because of distortion it might cause and may not be machinable afterwards.
 
You cant just upsize that bolt one size and retap the hole? That's what I'd do.


Per the machine shop the hole is at least 2 steps larger. And about as large as their largest drill bit for thread repair kit. And one of the holes is oval. I guess I need to do some research. I saw ezlok has thick steel inserts. Will have to take measurement.
 
No, they just did not want to bother with it.

Still a fairly simple fix...

You will do about the same thing as what is shown in the 2 following repairs.

http://www.dsmtuners.com/threads/broken-exhaust-stud-repair.457207/

http://www.dsmtuners.com/threads/turbo-oil-feed-port-repair.466235/

That looks to be a 10mm bolt, if thats the case, drill and tap for a 3/8 pipe plug

You may need to use 2 taps, a full length one, and then cut down the other so you can get the pip plug fully in.
Just take your time and set the pip plugs flush, tap and check with the pipe plug.

Then once the pipe plug is in and tight, drill thu the pipe plug and tap to the bolt you need to use.
 
No, they just did not want to bother with it.

Still a fairly simple fix...

You will do about the same thing as what is shown in the 2 following repairs.

http://www.dsmtuners.com/threads/broken-exhaust-stud-repair.457207/

http://www.dsmtuners.com/threads/turbo-oil-feed-port-repair.466235/

That looks to be a 10mm bolt, if thats the case, drill and tap for a 3/8 pipe plug

You may need to use 2 taps, a full length one, and then cut down the other so you can get the pip plug fully in.
Just take your time and set the pip plugs flush, tap and check with the pipe plug.

Then once the pipe plug is in and tight, drill thu the pipe plug and tap to the bolt you need to use.

I decided to attempt to fix this myself since the machine shops do not want to mess with it.

One hole I was able to tap to m14x1.5. So the inserts that I ordered should work for this one. The other hole is oval with jb weld and was already a bit larger than 31/64 drill bit. I ran the tap and there are slight threads but won't be a good hold. So can I use jb weld or some metallic epoxy to strengthen the insert or would I have to go to m16? Since it's oval already it will be off center. So the bracket will need to be drilled.
 
Your half shaft bolts are normally 10mm. I just discovered, during motor install, that MY block had a broken bolt in the inside hole. I drilled, progressively, with bits, increasing the drill size a little at a time and luckily got it out. I went to our local Fastenal and bought 12.2 grade bolts to put back in, as the one that I removed was very soft. You will probably have to drill out your bracket for the proper size that you end up with.
 
sorry to bring up an old thread! but im having the same issue as the op. my motor is still in the car, its a 90 tsi awd. can i drop the motor down enough from the bottom to use a tap? with the motor still in place i cant fit a tap back there. just not enough room. has anyone else done this? help would be appreciated.
 
i can try, but im not sure it would work. its either that or take the intake manifold off so i can see what im doing. or drop the engine like 6-8 inches. not sure what the best way to go at it would be. pretty frustrating LOL
 
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