Tools Required

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert. During the insert installation process, the installation driver tool cold-rolls the bottom internal threads and expands the bottom external threads of the insert into the base material. This action mechanically locks the insert into place.

The tool kit J 42385-200 is designed for use with either a suitable tap wrench or drill motor. Limited access and larger hole repair may process better using a tap wrench. An extension J 43965 may also be necessary to drive the thread repair tooling dependent on access to the hole being repaired.

It is critical that the drilling, counterboring and tapping of the hole to be repaired follows the same centerline as the original hole.

During the drilling and tapping of the hole being repaired ensure the tooling is consistently machining perpendicular to the surface of the base material.

If the threaded hole being repaired has a base surface perpendicular to the hole centerline, tapping guides are available to aid in tapping the hole.

Caution: Wear safety glasses in order to avoid eye damage.

Important: The use of a cutting type fluid GM P/N United States 1052864, GM P/N Canada 992881, WD 40® or 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 the counterbore of the drilled/tapped hole and just below the surface (2) of the base material.

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.

Important: Do NOT drill any further than the original hole depth.

1. Drill out the threads of the damaged hole.

•	M6 inserts require a minimum drill depth of 15 mm (0.59 in).

•	M8 inserts require a minimum drill depth of 20 mm (0.79 in).

•	M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).





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

2. Using compressed air, clean out any chips.




Important: A properly counterbored hole will show a slight burnishing on the surface of the base material for 360 degrees around the drilled hole.

3. Counterbore the drilled hole to the full depth permitted by the tool (1).




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

4. Using compressed air, clean out any chips.




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.

Important: Ensure the tap has created full threads at least to the depth equal to the insert length.

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

•	M6 inserts require a minimum tap depth of 15 mm (0.59 in).

•	M8 inserts require a minimum tap depth of 20 mm (0.79 in).

•	M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).





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

6. Using compressed air, clean out any chips.



7. Spray cleaner GM P/N United States 12346139, GM P/N United States 12377981, GM P/N Canada 10953463, or equivalent into the tapped hole.




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

8. Using compressed air, clean out any chips.




Important: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.

9. Lubricate the threads of the driver installation tool (2) with the driver oil (1) J 42385-110.



10. Install the insert (2) onto the driver installation tool (1).



11. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).



12. Install the insert (2) into the tapped hole.




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.

13. Install the insert until the flange (2) of the insert contacts the counterbored surface.




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.

14. Continue to rotate the driver installation tool (1) through the insert (2).



15. Inspect the insert for proper installation into the tapped hole. A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).



16. 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.

Caution: Wear safety glasses in order to avoid eye damage.

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

Important: 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.

1. Install a stop collar (2) on the counterbore drill (1), if required.




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.

Important: Drill the hole until the stop collar contacts the surface of the base material.

2. Drill out the threads of the damaged hole.




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

3. Using compressed air, clean out any chips.




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.

Important: 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.




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

5. Using compressed air, clean out any chips.



6. Spray cleaner GM P/N United States 12346139, GM P/N United States 12377981, GM P/N Canada 10953463, or equivalent into the tapped hole.




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

7. Using compressed air, clean out any chips.




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.



9. Install the insert (2) onto the driver installation tool (1).



10. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).



11. Install the insert (2) into the tapped hole.




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.




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).



14. Inspect the insert (1) for proper installation (2) into the tapped hole.



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.

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

Caution: Wear safety glasses in order to avoid eye damage.

Important: The use of a cutting type fluid GM P/N United States 1052864, GM P/N Canada 992881, WD 40® or 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.

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.

Important: Drill the hole until the stop collar contacts the surface of the base material.

1. Drill out the threads of the damaged hole.




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

2. Using compressed air, clean out any chips.




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.

Important: Ensure the tap has created full threads at least to the depth equal to the insert length.

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



4. Tap the drilled hole until the threads at the top of the tap (2) are down to the surface of the base material.




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

5. Using compressed air, clean out any chips.



6. Spray cleaner GM P/N United States 12346139, GM P/N United States 12377981, GM P/N Canada 10953463, or equivalent into the tapped hole.




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

7. Using compressed air, clean out any chips.




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.



9. Install the insert (2) onto the driver installation tool (1).



10. Apply threadlock sealant GM P/N United States 12345493, GM P/N Canada 10953488, J 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2).



11. Install the insert (2) into the tapped hole.




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.

12. Install the insert until the flange (2) of the insert contacts the surface of the base material.




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) until the top of the threaded section (2) is level with the top of the insert (3).



14. Inspect the insert (1) for proper installation (2) into the tapped hole.



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.

Tools Required

1. The cylinder head bolt hole thread repair kit J 42385-600 and J 42385-300 consists of the following items:

•

Drill (1)

•

Tap (2)

•	Installer (3)

•	Stop collar (4), for shallow holes

•	Alignment pin (5)

•	Bushing (6)

•

Bolts (7)

•	Fixture plate (8)





Caution: Wear safety glasses in order to avoid eye damage.

Important: The use of a cutting type fluid GM P/N United States 1052864, GM P/N Canada 992881, WD 40®, or equivalent is recommended when performing the drilling and tapping procedures.

Driver oil MUST be used on the installer driver tool.
The tool kits J 42385-600 and J 42385-300 are designed for use with either a suitable tap wrench or drill motor.
2. Install the fixture plate (3), bolts (2), and bushing (1) onto the engine block deck.

Position the fixture plate and bushing over the hole that is to be repaired (4).




3. Position the alignment pin (1) through the bushing and into the hole.
4. With the alignment pin in the desired hole, tighten the fixture bolts (2).
5. Remove the alignment pin from the hole.
6. The left cylinder head bolt holes 805 - 808 are deep holes and will be drilled without an additional stop collar.
7. The left cylinder head bolt holes 801 - 804 are shallow holes and will be drilled with an additional stop collar.
8. The right cylinder head bolt holes 705 - 708 are deep holes and will be drilled without an additional stop collar.
9. The right cylinder head bolt holes 701 - 704 are shallow holes and will be drilled with an additional stop collar.



10. Install the stop collar (2) onto the drill (1) if required.




Important: During the reaming process, it is necessary to repeatedly remove the drill and clean the chips from the hole.

11. Drill out the threads of the damaged hole.

Drill the hole until the stop collar of the drill bit or the added stop collar contacts the bushing.





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

12. Using compressed air, clean out any chips.



13. Using a tap wrench, tap the threads of the drilled hole.



14. In order to tap the new threads to the proper depth, rotate the tap into the hole until the marks (1 or 4) on the tap align with the top of the drill bushing (3).

For the deeper cylinder head bolt holes, 705-708 or 805-808, rotate the tap until the upper mark on the tap (4) aligns with the top of the drill bushing.

For the shallower cylinder head bolt holes, 701-704 or 801-804, rotate the tap until the lower mark on the tap (1) aligns with the top of the drill bushing.

15. Remove the fixture plate (2), bushing (3), and bolts.




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

16. Using compressed air, clean out any chips.



17. Spray cleaner GM P/N United States 12346139, GM P/N United States 12377981, GM P/N Canada 10953463, or equivalent into the hole.




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

18. Using compressed air, clean any cutting oil and chips out of the hole.




Important: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.

19. Lubricate the threads of the installer tool (2) with the driver oil (1).



20. Install the insert (2) onto the driver tool (1).



21. Apply threadlock Loctite® 277, J 42385-109 (1), or equivalent to the insert OD threads (2).




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.

22. Install the insert and driver (1) into the hole.

Rotate the driver tool until the mark on the tool aligns with the deck surface of the engine block.

Tools Required

1. The main cap bolt hole thread repair kit J 42385-600 and J 42385-300 consists of the following items:

•

Drill (1)

•

Tap (2)

•	Installer (3)

•	Fixture plate (4)

•	Long bolts (5)

•	Short bolts (6)

•	Alignment pin (7)

•	Bushing (8)





Caution: Wear safety glasses in order to avoid eye damage.

Important: The use of a cutting type fluid GM P/N United States 1052864, GM P/N Canada 992881, WD 40®, or equivalent is recommended when performing the drilling and tapping procedures.

Driver oil MUST be used on the installer driver tool.
The tool kits are designed for use with either a suitable tap wrench or drill motor.
2. Install the fixture plate, bolt, and bushing, onto the engine block.

Position the fixture plate and bushing over the hole that is to be repaired.

3. Position the alignment pin in the desired hole and tighten the fixture bolts.

Important: During the reaming process, it is necessary to repeatedly remove the drill and clean the chips from the hole.

4. Drill out the damaged hole. Drill until the stop collar of the drill bit or the sleeve contacts the bushing.




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

5. Using compressed air, clean out any chips.



6. Using the tap (4) and wrench, tap the threads of the drilled hole.




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

7. Using compressed air, clean out any chips.



8. Spray cleaner GM P/N United States 12346139, or equivalent into the hole.




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

9. Using compressed air, clean any cutting oil and chips out of the hole.




Important: Do not allow oil or other foreign material to contact the outside diameter (OD) of the insert.

10. Lubricate the threads of the installer tool (2) with the driver oil (1).



11. Install the insert (2) onto the driver tool (1).



12. Apply threadlock Loctite® 277, J 42385-109 (1), or equivalent to the insert OD threads (2).




Important: The fixture plate and bushing remains installed onto the engine block during the insert installation procedure.

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. Install the insert and driver (1) through the fixture plate and bushing and into the hole.

Rotate the driver tool until the mark on the tool (3) aligns with the top of the bushing (2).