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Old 08-21-2004, 12:01 PM   #1
burt_poppenga
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WRB

Default Help with stripped nut on rear diff support

Hello,

I was installing the Whiteline rear diff bushings on my 04 STI and ran into a problem with one of the differential mount bracket bolts. It started when I tried to take one of the small bolts off the drivers side bracket: it looks like it was cross threaded from the factory.

I got the bolt out but it was really messed up. The nut up inside the body didn't look too bad, so I got a new bolt to replace the old one.

No dice. It is clear that the nut (up inside the body) is completely hosed. How do you fix somthing like that?

Thanks,
Burt
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Old 08-21-2004, 01:41 PM   #2
OneOBS
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If you have a tap & die set ($12 at Harbor Freight), you can try to clean up the threads in the nut and use a new bolt. If that doesn't work, tap it out slightly and use a larger diameter bolt.
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Old 08-21-2004, 07:47 PM   #3
burt_poppenga
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I stopped by Harbor Freight, they had a nice metric 40 piece tap set on sale for $9.

I used the 8x1.25 tap and it really cleaned the threads up nicely. Problem now is the hole is just a tad bigger than the new 8x1.25 bolt. Don't know what I did wrong ... but the bolt wiggles around badly (and can't be snugged up or it pulls the thread out).
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Old 08-21-2004, 07:59 PM   #4
OneOBS
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Uh-oh. You'll need a bigger bolt, then.
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Old 08-21-2004, 08:43 PM   #5
burt_poppenga
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I was just down at the hardware store. The next size up in a metric bolt with a 1.25 thread is 10mm. That could be a bit big for the available space.

The SAE bolts had completely different thread pitches, don't know if I can run a tap through and expect it to work or not.

What size bolt/tap would you suggest?

If all that doesn't work, is is possible to have the 'nut' replaced? I can't see an obvious way to get access to it ... it doesn't come through to the inside of the car. Looks like its inside the frame someplace.

Doh.
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Old 08-24-2004, 12:59 AM   #6
burt_poppenga
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I talked to my dealer today and they didn't have any good ideas on how to replace the nut, so I ended up buying a heli-coil thread repair kit. I had to shorten the insert a little bit, but it came out really well.
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