LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2009 >> Corvette Base, 2D Convertible, Automatic >> Repair and Diagnosis >> Body & Frame >> Frames, Subframes & Crossmembers >> Frame And Underbody >> Repair Instructions >> Aluminum Frame Thread Repair (Z06, ZR1) >> Thread Repair Procedure

Thread Repair Procedure

    Fig 1: Identifying Extracting Tool
    GM1705973Courtesy of GENERAL MOTORS CORP.
    WARNING: Refer to Safety Glasses Warning .
  1. The suspension thread repair procedure involves a solid, thin-walled, key-locking, stainless steel keysert. Use the keysert when the parent material of the original threaded insert is damaged.

    Install the CH-48106-1 extracting tool (1) into the damaged wire insert.

  2. Set the extracting tool by lightly tapping the tool with a mallet.
  3. Remove the wire insert by turning the tool counterclockwise, while applying light forward pressure on the tool.
    4. Fig 2: Illustrating Drilling Out Threads
    GM1706080Courtesy of GENERAL MOTORS CORP.
  4. Use the CH-48106-2 12.8 mm drill bit to drill out the threads of the damaged hole. Drill to a minimum depth of 14.5 mm (3/8 in).
    5. Fig 3: Cleaning Out Chips With Compressed Air
    GM1706064Courtesy of GENERAL MOTORS CORP.
  5. Use compressed air (1) to clean out any chips.
    6. Fig 4: Countersinking Hole
    GM1706079Courtesy of GENERAL MOTORS CORP.
    NOTE: The keysert will install more easily if you countersink the hole.
  6. Use a CH-48106-3 chamfering tool or an oversize drill bit of 14.25 mm (3/8 in) to countersink the drilled-out hole.
    7. Fig 5: View Of Cleaning Out Chips
    GM1706064Courtesy of GENERAL MOTORS CORP.
  7. Use compressed air (1) to clean out any chips.
  8. Use CH-48106-8 cutting oil to lubricate the threads of the tap.
  9. Install the CH-48106-6 tap socket or equivalent tool to the CH-48106-4 tap.
    10. Fig 6: Tapping New Threads
    GM1706081Courtesy of GENERAL MOTORS CORP.
  10. Use the CH-48106-4 M14-1.5 6H Tap (1) to tap new threads in the drilled hole. Tap the threads to a minimum depth of 13.5 mm (5/16 in).
    11. Fig 7: Cleaning Out Chips With Compressed Air
    GM1706064Courtesy of GENERAL MOTORS CORP.
  11. Use compressed air (1) to clean out any chips.
    12. Fig 8: View Of CH-48106-5 Installation Tool
    GM1706279Courtesy of GENERAL MOTORS CORP.
  12. Install the CH-48106-7 keysert into the slotted sections of the CH-48106-5 installation tool (1).
    13. Fig 9: View Of Installing keysert In Tap Hole
    GM1706298Courtesy of GENERAL MOTORS CORP.
  13. Use the CH-48106-5 installation tool to install the keysert in the tap hole slightly below the bottom of the countersunk surface (1).
  14. Remove the CH-48106-5 installation tool from the keys. Rotate the tool so that the keys are aligned on the flat surface of the tool.
    NOTE: The keys mechanically lock the keysert to the threaded parent material.
    15. Fig 10: View Of Driving In Keys
    GM1706309Courtesy of GENERAL MOTORS CORP.
  15. Use a mallet to strike the top of the CH-48106-5 installation tool (1) as necessary to drive the keys into the threaded parent material until the keys are even or slightly below the surface.
    16. Fig 11: Inspecting Keysert Installation
    GM1706311Courtesy of GENERAL MOTORS CORP.
    NOTE: If necessary, add shims or washers to the suspension bolt to check the torque and flushness of the bolt.
  16. Inspect the keysert (1) for proper installation into the hole.
  17. Temporarily install the suspension bolt, then tighten to 91 N.m (67 lb ft).
  18. Verify that the suspension bolt is seated flush to the surface.
scientia non olet · About LEMON Manuals