Standard Thread Repair - Flush Hole

Fig 1: Identifying Base Material Surface And Flange

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Refer to SAFETY GLASSES WARNING .

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.

1. NOTE:

   • During the drilling process, it is necessary to repeatedly remove the drill and clean chips from the hole and the flutes of the drill.
   • Do NOT drill any further than the original hole depth.

   Drill out the threads of the damaged hole.

   Specifications 

   • 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).
   Fig 2: Drilling Out Damaged Hole Threads

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

   Using compressed air, clean out any chips.

   Fig 3: Removing Drilled Hole Chips Using Compressed Air

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

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

   Fig 4: Counterboring Drilled Hole To Full Depth Using Tool

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

   Using compressed air, clean out any chips.

   Fig 5: Removing Drilled Hole Chips Using Compressed Air

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4. NOTE:

   • During the tapping process, it is necessary to repeatedly remove the tap and clean chips from the hole and the flutes of the tap.
   • Ensure the tap has created full threads at least to the depth equal to the insert length.

   Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.

   Specifications 

   • 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).
   Fig 6: Tapping Drilled Hole Threads Using Tapping Wrench

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

   Using compressed air, clean out any chips.

   Fig 7: Removing Drilled Hole Chips Using Compressed Air

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2. Spray cleaner into the tapped hole. Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS  for recommended cleaner.
   Fig 8: Spraying Cleaner Into Tapped Hole

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

   Using compressed air, clean out any chips.

   Fig 9: Removing Drilled Hole Chips Using Compressed Air

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

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

   Fig 10: Lubricating Driver Installation Tool Threads

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5. Install the insert (2) onto the driver installation tool (1).
   Fig 11: Installing Insert Onto Driver Installation Tool

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6. Apply threadlock sealant, EN 42385-109, LOCTITE 277® or equivalent (1) to the insert OD threads (2). Refer to ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS  for recommended sealant.
   Fig 12: Applying Threadlock Sealant To Insert OD Threads

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7. Install the insert (2) into the tapped hole by hand only.
   Fig 13: Installing Insert Into Tapped Hole

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8. NOTE: 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.

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

9. NOTE: 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.

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

   Fig 14: Rotating Driver Installation Tool Through Insert

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10. 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).
    Fig 15: Identifying Base Material And Insert

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11. 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.
    Fig 16: Identifying Base Material, Engine Coolant Passage And Insert

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