Tapered Pipe Thread Repair

WARNING: This page is about a different car, the 2003 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.

The thread repair insert for tapered pipe threads is coated with a clear silver zinc coating.

CAUTION: Refer to SAFETY GLASSES CAUTION .

Important: The use of a cutting type fluid GM P/N 1052864, (Canadian P/N 992881), WD 40® equivalent is recommended when performing the drilling, counterboring and tapping procedures.

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

Fig 1: Locating Flange Of Insert & Surface Of Base Material

Courtesy of GENERAL MOTORS CORP.

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.

Drill out the threads of the damaged hole.

Fig 2: Drilling Out Threads Of Damaged Hole
Courtesy of GENERAL MOTORS CORP.

Important: All chips must be removed from the drilled hole prior to tapping.
Using compressed air, clean out any chips.

Fig 3: Removing Chips From Drilled Hole
Courtesy of GENERAL MOTORS CORP.

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

Fig 4: Tapping Threads Of Drilled Hole
Courtesy of GENERAL MOTORS CORP.
Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the base material.

Fig 5: Tapping Drilled To Surface Of Base Material
Courtesy of GENERAL MOTORS CORP.

Important: All chips must be removed from the tapped hole prior to insert installation.
Using compressed air, clean out any chips.

Fig 6: Removing Chips From Drilled Hole
Courtesy of GENERAL MOTORS CORP.
Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent into the tapped hole.

Fig 7: Spraying Cleaner Into Tapped Hole
Courtesy of GENERAL MOTORS CORP.

Important: All chips must be removed from the tapped hole prior to insert installation.
Using compressed air, clean out any chips.

Fig 8: Removing Chips From Drilled Hole
Courtesy of GENERAL MOTORS CORP.

Important: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.
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
Courtesy of GENERAL MOTORS CORP.
Install the insert (2) onto the driver installation tool (1).

Fig 10: Installing Insert Onto Driver Installation Tool
Courtesy of GENERAL MOTORS CORP.
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: Applying Threadlock Sealant To Insert OD Threads
Courtesy of GENERAL MOTORS CORP.
Install the insert (2) into the tapped hole.

Fig 12: Installing Insert Into Tapped Hole
Courtesy of GENERAL MOTORS CORP.

Important: If the insert will not thread down until the flange contacts the surface of the base material remove the insert immediately with a screw extracting tool and inspect the tapped hole for any remaining chips and/or improper tapping.
Install the insert until the flange (2) of the insert contacts the surface of the base material.

Fig 13: Installing Insert Until Flange Of Insert Contacts Surface Of Base Material
Courtesy of GENERAL MOTORS CORP.

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.
Continue to rotate the driver installation tool (1) until the top of the threaded section (2) is level with the top of the insert (3).

Fig 14: Rotating Driver Installation Tool To Top Of Insert
Courtesy of GENERAL MOTORS CORP.
Inspect the insert (1) for proper installation (2) into the tapped hole.

Fig 15: Inspecting Insert For Proper Installation Into Tapped Hole
Courtesy of GENERAL MOTORS CORP.
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: Checking Engine Coolant Passage
Courtesy of GENERAL MOTORS CORP.