Recessed Thread Repair

Important: 

• The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40® or equivalent is recommended when performing the drilling, counterboring and tapping procedures.
• Do NOT remove the original stop collar from a counterbore drill.

When installed to the proper depth, the flange of the insert (1) will be seated against the counterbore (2) of the drilled/tapped hole.

Fig 1: Identifying Flange Insert Seating

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1. Install a stop collar (2) on the counterbore drill (1), if required.
   Fig 2: Installing Stop Collar On Counterbore Drill

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   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 surface of the base material.
2. Drill out the threads of the damaged hole.
   Fig 3: Drilling Damaged Hole Thread

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

3. Using compressed air, clean out any chips.
   Fig 4: Removing Chips From Drill Hole

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   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.
4. Using a suitable tapping wrench, tap the threads of the drilled hole.
   Fig 5: Tapping Drilled Hole

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

5. Using compressed air, clean out any chips.
   Fig 6: Removing Chips From Drill Hole

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6. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.
   Fig 7: Applying Spray Cleaner To Tapped Hole

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

7. Using compressed air, clean out any chips.
   Fig 8: Removing Chips From Drill Hole

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   Important:  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 driver oil (1) J 42385-110.
   Fig 9: Lubricating Threads Of Driver Installation Tool

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9. Install the insert (2) onto the driver installation tool (1).
   Fig 10: Installing Insert Onto The Driver Installation Tool

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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 11: Apply Threadlock Sealant To Insert Threads

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11. Install the insert (2) into the tapped hole.
    Fig 12: Installing Insert Into Tapped Hole

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    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.

12. Install the insert until the flange (2) of the insert contacts the counterbored surface.
    Fig 13: Identifying Insert & Insert Flange

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    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.

13. Continue to rotate the driver installation tool (1) through the insert (2).
    Fig 14: View Of Insert Position

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14. Inspect the insert (1) for proper installation (2) into the tapped hole.
    Fig 15: Identifying Properly Installed Insert

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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.
    Fig 16: View Of Engine Coolant Passage In Insert

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