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Old 02-19-2008, 11:15 PM   #1
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Default Nothing is easy -> stripped egr threads

ok, so i'm almost thru mechanical install on begi 3 system, just waiting for a few clamps, the ECU (megasquirt, which i may need help with upon arrival), and a new throttle body inlet tube (the one with kit had the bung for air intake temp sensor in a bad spot). since it was "mostly" trackday car, it became "only" a track car and desided to remove lots of stuff (if anyone needs something let me know), one of which was the egr tub and valve, begi fabbed up a couple of nice alum plates (looked easy enough, 2 bolts here, 2 bolts there) well the tube plate went effortless, the valve on the other hand was in pretty good and took some force to get out, so upon installing the plate i figured tighten her up and then on the inside one i lost the threads on the intake manifold. so what are my options? JBweld? re-tap bigger size? or must be welded?
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Old 02-19-2008, 11:24 PM   #2
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I would try to run a tap thru it and clean up the threads, and then put the bolt back in. When you reinstall the bolt, use a lubricant and don't cross thread it, and don't overtighten it. You could remove the intake and drill it larger and install a helicoil, or drill it larger and tap it next size up, but I wouldn't. If this were a head bolt yea, helicoil. This is minorly significant so I would try to clean up the stripped threads and see if you can get a bolt just tight enough to do the job. If not, I'm gonna say pull the manifold and drill it.

Also, you should not have been trying to tighten those bolts too tight anyway. If your not confident use a torque wrench
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Old 02-19-2008, 11:30 PM   #3
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just use a self threading bolt of next size up...hell, worst case scenario you get a used mani for around $50
good luck
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Old 02-20-2008, 12:15 AM   #4
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have been using "the force" with regards to torque so far, if it was pretty tight to get off, i figure should be pretty tight when putting it back. i dont think i crossed it, i think i bottomed it out. if it doesnt have to be as tight as it was, then i think i can just re tap it, there seems to be some meat left in it. anyone know what size tap to get?
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Old 02-20-2008, 12:40 AM   #5
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Quote:
Originally Posted by squidgsxr View Post
have been using "the force" with regards to torque so far, if it was pretty tight to get off, i figure should be pretty tight when putting it back. i dont think i crossed it, i think i bottomed it out. if it doesnt have to be as tight as it was, then i think i can just re tap it, there seems to be some meat left in it. anyone know what size tap to get?
Not sure on the tap just bring the bolt that goes in the hole with you and match it up, or buy a screw pitch guage and measure the pitch, or you could buy a caliper and measure the major diameter and the pitch and calculate the size that way. Yea just because it was tight as hell before dosn't mean put it back that way. You can only torque a bolt to a certain amount, and that varies depending on if the threads are dirty, clean, oiled, or lubed with a moly-based lube. Do some research on it for 10 minutes and you'll know what I'm talking about. This could have been prevented, and you need to know stuff like this before you go installing a 2K dollar turbo kit.
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Old 02-20-2008, 01:31 AM   #6
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the bolt is fine, its the threads on the intake manifold that are gone (mostly), as long as it is a mission critical seal, you think i need a gasket, or just the alum should seat good enough, if the torque needed isnt as tight as it was, say its in the "medium" range then i think re tapping might be a viable option.
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Old 02-20-2008, 01:37 AM   #7
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yes you need a gasket to seal it the egr valve should have had one on it, use that one. Go buy a torque wrench.
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Old 02-20-2008, 01:53 AM   #8
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i bought one, just not a little one, i apparantly should add it to the collection
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