Help with stripped nut on rear diff support

Burt · 08-21-2004, 06:09 PM

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

Burt · 08-21-2004, 06:10 PM

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).

Burt · 08-21-2004, 06:11 PM

Someone suggested a larger size bolt, so I took a trip to 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.

jrich523 · 08-23-2004, 08:08 AM

sounds like your on the right track but i think perhaps you should have gone with a better tap set.
Im not sure how much larger you can go but im not so sure you can replace the 'nut'
thats really horrible tho... i would be crying..
I dont recall what there is for space but you might want to do a little more digging for better bolts and maybe a better tap.. i cant imagin a $9 tap set will be of high quality, which may explain the wiggle.

sorry i cant give any great advice.. just felt bad about your situation.. and you talking to yourself

good luck..

Burt · 08-23-2004, 10:02 PM

Damn, I was talking to myself again. I hate it when that happens.

I talked to my dealer and they didn't have any bright 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.

08-21-2004, 06:09 PM	#1
Burt Amateur STI Driver Posts: 34 IWSTI Addict since: Feb 2004 Trader Rating: (0)	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 This ad is not endorsed by this member. Please register or login to hide this ad.

08-21-2004, 06:10 PM	#2
Burt Amateur STI Driver Posts: 34 IWSTI Addict since: Feb 2004 Trader Rating: (0)	Help with stripped nut on rear diff support 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).

08-23-2004, 10:02 PM	#5
Burt Amateur STI Driver Posts: 34 IWSTI Addict since: Feb 2004 Trader Rating: (0)	Damn, I was talking to myself again. I hate it when that happens. I talked to my dealer and they didn't have any bright 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. This ad is not endorsed by this member. Please register or login to hide this ad.

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08-21-2004, 06:11 PM	#3
Burt Amateur STI Driver Posts: 34 IWSTI Addict since: Feb 2004 Trader Rating: (0)	Someone suggested a larger size bolt, so I took a trip to 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.

08-23-2004, 08:08 AM	#4
jrich523 Spec C Club Car: 04 black STI Fav Mod: short shifter Location: MA Posts: 1,081 IWSTI Addict since: Mar 2004 Trader Rating: (0)	sounds like your on the right track but i think perhaps you should have gone with a better tap set. Im not sure how much larger you can go but im not so sure you can replace the 'nut' thats really horrible tho... i would be crying.. I dont recall what there is for space but you might want to do a little more digging for better bolts and maybe a better tap.. i cant imagin a $9 tap set will be of high quality, which may explain the wiggle. sorry i cant give any great advice.. just felt bad about your situation.. and you talking to yourself good luck..