Loose thread-inserts in intake manifold.

[12Ounce]

Some folks have posted about this problem before ...
http://www.automotiveforums.com/vbul...ntake+manifold
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I use a torque wrench and thought the loose thread-insert curse would never visit me ... but Voila' ... there it was; the intake manifold bolt turning with no effect.

The Escape! As I have suggested before, I used my rotary grinder to grind away the bolt head. The bolt will get very hot and melt the manifold plastic if one does not douse with water often. After the bolt head is cut away the upper manifold can be separated from the spacer ... but what then??

The Final Solution! Gather up 14 screws from Home Depot or such ... 6mm x 1.0 x 40mm long ... and some nuts. Run the screws upward through the inserts and you now have "studs" for attaching the upper. No more chances for loose inserts! ( I could make a photo if anyone needs. ??)

[onit]

Please if possible can you put up some pics of this. I am trying to visualize this in my head but i am having a hard time seeing this.

[Windywoes]

12Ounce I must have read your mind. That was Plan B for me. Plan A was to cut the heads off the bolts but then try and remove the threaded inserts and re-seat them with epoxy. Since Plan B is easier it might be my preferred Plan. Now, I have to buy a Dremel (been putting this off for far too long) and the bolts/nuts. Of course my preferred store is Lowe's (Jimmy fan; not Logano fan) so I will look there first.

Thanks 12Ounce.

[12Ounce]

If you haven't already bought the rotary tool ... you may want to consider the Black and Decker model. I find it tougher than the Dremel. (I've had some of each.) But if you are going to be doing tiny, tiny work ... the Dremel may be best for you. The B&D has a slightly larger chuck ... and the usual tools are a bit larger and more rugged. Home Depot, maybe Lowe's .... I'm not sure.

[Windywoes]

Thanks for the grinder advice, but I think I will opt for the Dremel as I often have a need for a smaller tool. I also have a Roto-zip and that gets a little big for more delicate work.

Thanks also for the metric thread size on the bolts!

[12Ounce]

Trying for the photo:
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OOPS! I was supposed to reduce the file I suppose ... I thought it was automatic.

I put studs under the IAC valve also. The screws are unmatched in length, ... easy to see. Got what was available.

[Windywoes]

The Dremel I bought was BOB (bad out of box) in that the on/off switch worked intermittently. But when it did work it was an amazing tool at cutting off the two bolt heads that were turning on me. I bought the larger diameter thin abrasive wheels. Hardly any wear and the wheel did not seem to generate much heat-probably because it is so thin.

Well, at any rate, I got Windy back together and she still misses like before. Next work is clean injectors, check coil more closely, and change plugs.