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Aluminium head exhaust bolts

Tiny
JCLEMO
  • MEMBER
  • 1997 NISSAN HARDBODY
  • 2.4L
  • 4 CYL
  • 2WD
  • MANUAL
  • 238,000 MILES
I have a stripped bolt it was broken.
I drilled out the stud and tapped it.
I used a 5/16-18 helicoil and new bolt.
Helicoil failed. I did not re-drilled but used a 3/8 tap and cut new threads.
Replaced bolt with a 3/8-16 thread. And it too is failing. Problem being it will not pull the manifold tight enough to stop the leak. Should I have used a metric bolt? Something a little bigger?
Please any advise I do not want to pull this head again if there is an alternative. Thanks. JC
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Tuesday, January 15th, 2019 AT 12:04 AM

3 Replies

Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Good morning,

I am wondering why the helicoil did not work. If you drilled the hole for the 5/16 heli coil, it was bigger than 3/8.

At this point, you need to remove the head and have a machine shop insert a larger heli coil, install a bolt and then cut it off even with the head. Then drill the stud back to 5.16 so you can assemble the manifold.

The other alternative is to replace the head.

Roy
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Tuesday, January 15th, 2019 AT 4:09 AM
Tiny
JCLEMO
  • MEMBER
  • 161 POSTS
Sounds like good idea. Thanks. By the way when installing new studs head studs I'm talking about should thread locker be used? Thanks
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Tuesday, January 15th, 2019 AT 4:44 AM
Tiny
ASEMASTER6371
  • MECHANIC
  • 52,797 POSTS
Yes, definitely use thread sealer.

You are welcome.

Always glad to help.

Roy
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Tuesday, January 15th, 2019 AT 4:46 AM

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