Stripped Threads - Drain Plug - Repair

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Stripped Threads - Drain Plug - Repair

Post by Booga-dune-poon » Sat Jan 29, 2011 11:20 pm

Symptom: Leaking gear oil from drain plug.
Diagnosis: Stripped threads in aluminum engine case due to steel drain plug threads either over torqued or cross threading.
Treatment: Install Timesert steel thread insert.

Victim: 1996 Honda CR250 motorcycle
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Special tools: Timesert drain plug repair kit
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Common tools: 3/8" rachet, 7/16" 12 point socket to drive drill bit and tap

Repair Instructions:

Step 1 - dip drill bit in grease to help capture chips during drilling operation
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Step 2 - drill out drain hole oversize removing existing threads (pay special care to drill hole straight)
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Step 3 - clean out metal chips from drain hole (I used Q-tips dipped in grease paying special care to not push any inside the gear box)
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Re: Stripped Threads - Drain Plug - Repair

Post by Booga-dune-poon » Sat Jan 29, 2011 11:28 pm

Step 4 - Use counterboring tool to create a step in the hole
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Step 5 - Use tap guide and tap (pay special care to keep this straight)
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Re: Stripped Threads - Drain Plug - Repair

Post by Booga-dune-poon » Sat Jan 29, 2011 11:52 pm

Step 6 - remove tap and clean out threads with Q-tips with grease, then brake cleaner
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Step 7 - install Timesert metal insert by hand
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Step 8 - using the installation tool, drive the insert down seating it in the counterbore step (at first you'll feel the threads tightening and then the install tool will move freely. This is feedback that the steel threads have locked the insert into the aluminum case).
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Step 9 - remove the installation tool and admire the steel threads that will no longer be vulnerable to stripping again.
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Step 10 - install drain plug with washer and torque to manufacturers specifications.
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Bottom line - it took about 1 hour to make this repair including stopping to take the pictures. The repair kit in my case was a metric M12 x 1.50 costing $93.00 over the internet. I still have 4 more inserts that came with the kit so I suppose I could fix the aluminum oil pans in my motorhome, automobiles, quad or other motorcycles if they should ever need a fix. If you can change a light bulb or the flapper in a toilet tank, then you can make this repair too.
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Re: Stripped Threads - Drain Plug - Repair

Post by Glamisbound » Sun Jan 30, 2011 8:19 pm

Very nice "how to". Thanks for posting.
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Re: Stripped Threads - Drain Plug - Repair

Post by RobC » Mon Jan 31, 2011 7:21 am

Very nice. Thanks.
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Re: Stripped Threads - Drain Plug - Repair

Post by Sandcock » Tue Feb 08, 2011 6:54 pm

Totally cool 8) Do you make house calls :D
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Re: Stripped Threads - Drain Plug - Repair

Post by OLD GUY » Thu Feb 10, 2011 2:57 pm

Outstanding job. Not only did you show us all how to fix something you made lots of friends by doing it for =D> =D> :D :D a member.
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