Stripped threads on therm stat housing

[Dartmoor_Lad]

Putting the thermostat housing back on my 2.4 Mav on the middle of Dartmoor in the rain and wind....
Tried to rush the job and have stripped the internal threads so the housing wont tighten down now:doh.
Any easy but long term solutions suitable for an idiot?
On the plus side I found another leak from the water pum so have ordered a new one from Milners so if and when I get it back together it will have a new pump, rad, thermostat and housing cover.

Wonder what else can go wrong? I can't lie, I am getting close to fixing it and just selling it.

 

[rustic]

Putting the thermostat housing back on my 2.4 Mav on the middle of Dartmoor in the rain and wind....
Tried to rush the job and have stripped the internal threads so the housing wont tighten down now:doh.
Any easy but long term solutions suitable for an idiot?
On the plus side I found another leak from the water pum so have ordered a new one from Milners so if and when I get it back together it will have a new pump, rad, thermostat and housing cover.

Wonder what else can go wrong? I can't lie, I am getting close to fixing it and just selling it.

3 options.

1 Fit a larger diameter bolt, but this will require opening up the stat housing to suit the new bolt, and this may not have enough room around the bolt.
You will need a suitable bolt and a tap and re-drill and tap the base.

2 Fit a Helicoil, this require the base to be drilled with a helicoil drill and tap, and a spring like item is inserted into the hole. Most garages can do this while you wait. 10 minute job.... Get a few quotes.

For aluminium, this actually makes the bolt more secure and stronger than before, and you can use the original bolt.

3 You could drill the base deeper if there is enough metal, and re-tap the hole and get a longer bolt to suit, or use a length of "All Thread" and put a nut and washer on the top.

There are epoxy metals that you can use, which can be drilled and tapped...... BUT I wouldn't use it for a permanent repair, or if you ever needed to seperate it again..

Hope this helps.

 

[macabethiel]

Helicoils

I agree with the previous post.
I would go for a Helicoil they do work - find a reputable local engineering firm of engine rebuilders to do it.
Its an everday job for them. I had one done about 20 years ago it was the 11 th stud on a Cooper S cylinder head that had been overtightened and stripped. Kept the car for 11 years no problems despite removing the head for tuning purposes several times.

 

[Terranical]

I agree with the previous post.
I would go for a Helicoil they do work - find a reputable local engineering firm of engine rebuilders to do it.
Its an everday job for them. I had one done about 20 years ago it was the 11 th stud on a Cooper S cylinder head that had been overtightened and stripped. Kept the car for 11 years no problems despite removing the head for tuning purposes several times.

Defo helicoils - kit costs around £25, includes tap, correct size drill, usually 10 stainless steel inserts (hence a stronger repair when using in aluminium) and a punch to snap off the tang when the coil is fitted. All you will need is a tap wrench and an electric drill. I've used them for years in restoration of old motorbikes, and in my previous life as an engineer working on industrial size mailing machines. Kit is bought by size i.e. M4, M5 etc. From memory the thermostat housing has M8x1.25" pitch bolts, but don't quote me on that!

 

[rustic]

Defo helicoils - kit costs around £25, includes tap, correct size drill, usually 10 stainless steel inserts (hence a stronger repair when using in aluminium) and a punch to snap off the tang when the coil is fitted. All you will need is a tap wrench and an electric drill. I've used them for years in restoration of old motorbikes, and in my previous life as an engineer working on industrial size mailing machines. Kit is bought by size i.e. M4, M5 etc. From memory the thermostat housing has M8x1.25" pitch bolts, but don't quote me on that!

I bought mine for working on the leg of aluminium outboard engines.

For the same reason.

This is what a kit looks like, there are many manufacturers of similar tools.

http://cgi.ebay.co.uk/M8-X-1-25-X-1...591?pt=LH_DefaultDomain_3&hash=item3cb7b38a1f

We used them in Aluminium castings where the bolts were removed to gain access to a battery compartment.
They are really tough, better than plain aluminium.

If you are unsure, try one on a piece of scrap aluminium.

 

[Terranical]

I bought mine for working on the leg of aluminium outboard engines.

For the same reason.

This is what a kit looks like, there are many manufacturers of similar tools.

http://cgi.ebay.co.uk/M8-X-1-25-X-1...591?pt=LH_DefaultDomain_3&hash=item3cb7b38a1f

We used them in Aluminium castings where the bolts were removed to gain access to a battery compartment.
They are really tough, better than plain aluminium.

If you are unsure, try one on a piece of scrap aluminium.

Thats an excellent price Rustic, may consider topping some of mine up (last set I bought was M5, from Buck & Hickman Engineering Supplies, paid around £22 plus VAT, and they weren't even genuine Helicoil, some Australian make!)

 

[Dartmoor_Lad]

Thanks for all the replies guys. Got a kit on order from Amazon for £16 inc delivery. Thermostat housing bolts on the 2.4 are M6

 

[Terranical]

Thanks for all the replies guys. Got a kit on order from Amazon for £16 inc delivery. Thermostat housing bolts on the 2.4 are M6

Our purpose in life is to help!!!

 

[clivvy]

bit late into the thread, but yes, i'd go for helicoils too. I have a kit, from when I had to re drill and helicoil the engine mount bolt holes on my V6 Mazda engine, had to use removal tool, re drill the hole to fit the helicoil, then screw that in, pretty easy, and on the max should be a doddle as theres no obstruction.:thumb2

 

[(RIP) PLANK]

Thanks for all the replies guys. Got a kit on order from Amazon for £16 inc delivery. Thermostat housing bolts on the 2.4 are M6

are they a "normal" thread pitch?

 

[Terranical]

are they a "normal" thread pitch?

What's normal! Most Japanese automotive threads up to 10mm are 1.25" pitch whereas UK tend to be 1.5, so if you buy some, say, 6mm-10mm bolts from your local diy shed they will be 1.5" pitch. If you go to a specialist fastenings supplier they will stock both pitches. I mostly use Custom Fasteners in mid-Wales, partly because I nearly always use stainless steel, and partly because I have been using them for about 20 years to suit my Japanese motorbike restorations.

 

[(RIP) PLANK]

What's normal! Most Japanese automotive threads up to 10mm are 1.25" pitch whereas UK tend to be 1.5, so if you buy some, say, 6mm-10mm bolts from your local diy shed they will be 1.5" pitch. If you go to a specialist fastenings supplier they will stock both pitches. I mostly use Custom Fasteners in mid-Wales, partly because I nearly always use stainless steel, and partly because I have been using them for about 20 years to suit my Japanese motorbike restorations.

that was my point!

if you try a nut on your old bolts first you will know if they are 1.25 or 1.5 as it's highly unlikely you will have a 1.25 nut! If you have ordered 1.5 helicoil don't despair, just get some 1.5 bolts to suit and all will be well :thumb2

 

[Terranical]

that was my point!

if you try a nut on your old bolts first you will know if they are 1.25 or 1.5 as it's highly unlikely you will have a 1.25 nut! If you have ordered 1.5 helicoil don't despair, just get some 1.5 bolts to suit and all will be well :thumb2

Yo!

 

[briggie]

yo yo ?

 

[solarman216]

Just to throw a spanner in the works, just checked my spare petrol 2.4 engine T stat bolts and they are 6mm X 1mm pitch, Rick

 

[rustic]

Just to throw a spanner in the works, just checked my spare petrol 2.4 engine T stat bolts and they are 6mm X 1mm pitch, Rick

I hope I have removed the spanner out of the works...
Oh it's a 10mm AF spanner, just the job for those M6 bolts...:lol :lol

M6 x 1mm is your bog standard M6 bolt so most standard M6 kits will be this.

See
http://cgi.ebay.co.uk/M6-X-1-0-X-8-...646?pt=LH_DefaultDomain_3&hash=item3cb762f956

Should be fine.. unless you have ordered something different.
best regards, Rustic

 

[(RIP) PLANK]

if you have ordered soething different, just get new bolts to suit your kit :thumb2

 

[rustic]

if you have ordered soething different, just get new bolts to suit your kit :thumb2

A friend of mine once had a mini, there was a stabiliser bar that linked the top of the engine to the firewall, the bolt on the engine sheared, A common failure on Mini engines. So he drilled it out and re-tapped it to an M7 thread, since he had a tap this size, however....... no one locally had an M7 Bolt, and this was long before ebay. :doh

An M8 bolt was too large for the stabiliser bar, if only then he knew about Helicoils....:lol :lol :lol

 

[Dartmoor_Lad]

I have ordered the right helicoils kit, that's a relief!
However I did order a new waterpump with gasket from what appears to be a popular supplier. It turned up after 4 days with a 1-2 day delivery lead time, with no gasket. Upon phoning was told ah well can't you use just use a liquid gasket? Yes but thats not the point I ordered one with a gasket, well we dont sell them them on their own, so will get the pump collected and refund you, bye! M*****s? Should be renamed W*****s! Wont be getting any business from me again, and by the amount of money I am shelling out on this bloody Mav, it's their loss!


Rant Over!