Just did a TB tension check on the S4. Upon re-assembly, I discovered the threaded hole in the block for the long TB cover bolt is stripped. <img border="0" alt="[crying]" title="" src="graemlins/crying.gif" /> I put some red lok-tite on the bolt and torqued it gently. Top bolt hole is OK. Cover seems tight. I will repair the stripped hole permanently when I do a TB/WP change. Any suggestions on how to do this repair properly?

 

Re-thread the hole with a tap & die set. Basically it rethreads the hole.

<a href="http://www.amazon.com/exec/obidos/ASIN/B00004T9LR/ref%3Dnosim/lksmsubsite-sub-th-asin-20/104-1928644-2787918" target="_blank">http://www.amazon.com/exec/obidos/ASIN/B00004T9LR/ref%3Dnosim/lksmsubsite-sub-th-asin-20/104-1928644-2787918</a>

 

Just wondering what the next size up would be and how deep is the hole? Will I need a bottoming tap?

 

Or you could get a Heli-Coil™ kit for that bolt size.

One of my VW buddies says on performance air-cooled VWs, they Heli-Coil™ all the bolt holes as a matter of course when rebuiding.

 

Steve, take the bolt size (I think the oem size is 10mm) and go one/two up. Make sure you can find the same length bolt (Type) in the new size. Also make sure the new bolt will fit through the TB cover, if not, you may have to open the oem hole. For the depth, take a toothpick, or something of the sort that will bottom out and insert it into the hole, mark the stick when it bottoms out. Take the stick and mark the tap in relation to the depth.

The depth should relate to the bolt thread depth as well but .........you never know.

Heli- Coil works well, from what I hear, although I have no experience with it.

Hope this Helps

 

Best way to do this is with a HeliCoil, you still have to drill and tap but after you insert the HeliCoil you use the old bolt as it screws into the coil

<a href="http://www.hillcliff-tools.com/helicoil.html" target="_blank">http://www.hillcliff-tools.com/helicoil.html</a>

 

OT:

Zandramus: Is your spoiler missing? The front looks like something is missing, but clean?

 

Z-that is if his old bolt isn't stripped as well.

 

I bet a self tapping bolt one size larger would work well, after all the cover only weighs a few oz.

 

Use the Heli-coil! Its' easy to do, will keep the hardware original and is very durable. Napa Auto parts and others stock them. The kit isn't cheap, but once you use them you won't do it any other way. The refills of the coils are inexpensive. Just a quick note, when you buy the kit, buy the correct size drill bit for the kit and leave it in the kit for future use. Some of the drill bits required are "odd" sizes. They even work for head bolts!

 

Use a 'time-sert'?

<a href="http://forums.rennlist.com/cgi-bin/rennforums/ultimatebb.cgi?ubb=get_topic;f=14;t=001519" target="_blank">http://forums.rennlist.com/cgi-bin/rennforums/ultimatebb.cgi?ubb=get_topic;f=14;t=0015 19</a>

 

Thanks Randy. I hadn't ever heard of these, but will definetely try them. I am in the outboard marine repair business and we use Heli-coils all the time without any problems. "All the time" as aluminum blocks, stainless steel bolts, salt water... you get the picture! I looked up the info and ordered a catalog. Here's the link for anyone interested. <a href="http://www.timesert.com" target="_blank">www.timesert.com</a>
Bill