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Old 10-04-2018, 01:11 PM   #1
cgg17
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Default Timing Cover

Hello all,
I have been having an issue where the front third stud in the timing cover for the TAM mount kept loosening up. I finally decided to take off the TAM to see whats going on and here I found that the stud decided to rip the threads clean out of the aluminum timing cover. It is a straight hole down with zero treads.
Will a helicoil work for this? What size is the stud and has anybody done this before? I really do not want to do the timing cover, and if the helicoil doesnt work then I am just going to swap my old engine in it...
I have 16 days to do this before the show so time is of the essence.

...
1994 Sl2 5spd: 56,576 (Totaled 1/10/2018)
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Old 10-04-2018, 01:40 PM   #2
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Default Re: Timing Cover

http://www.saturnfans.com/forums/sho...d.php?t=171093

6mm X 1.0, but may want to wait for someone else to chime in

couple of reference threads. seems to be common
http://www.saturnfans.com/forums/sho...d.php?t=200241

http://www.saturnfans.com/forums/sho...d.php?t=198318

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Old 10-04-2018, 01:42 PM   #3
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Default Re: Timing Cover

Quick-fix #1: Clean out the hole, coat the stud with JB-Weld (or industrial equivalent/upgrade) and shove it in there. Don't expect to use it for at least 24hrs while the JB Weld fully cures.

Quick-fix #2: Get a M10x1.5x15mm coil kit, clean out the hole, tap the hole for the larger heli-coil size, insert heli-coil.

Long-fix: Get the right studs for the engine mount, get a new timing cover, swap the 'new' timing cover in.

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Old 10-04-2018, 02:02 PM   #4
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Default Re: Timing Cover

Helicoils are awesome. I have one in my airplane engine. Would be much easier than a timing cover swap. Probably a 20 minute job.

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Old 10-04-2018, 02:08 PM   #5
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Default Re: Timing Cover

Found an entire helicoil kit for $55.00, guess I am not replacing the CPS now!

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Old 10-04-2018, 08:35 PM   #6
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Default Re: Timing Cover

https://www.amazon.com/Helical-Threa...m+helicoil+kit

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'98 SC2, 5SP bought 2018

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Old 10-04-2018, 08:48 PM   #7
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Default Re: Timing Cover

I bought one at GS fasteners around the corner of me. Full kit, going to do it after class tomorrow afternoon.

...
1994 Sl2 5spd: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd Manual Swap: 150,062
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Old 10-04-2018, 08:54 PM   #8
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Default Re: Timing Cover

https://www.amazon.com/Helicoil-5546...KXNZZ5WH85EPN6

...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018

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Old 10-05-2018, 08:35 AM   #9
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Default Re: Timing Cover

I figured I would make this into a positive thing, and document the process of repairing the timing cover stud threads.

Attached are pictures of the damage, then the stud next to its original threads, and the new helicoil. Also a picture of the kit and it's contents.

...
1994 Sl2 5spd: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd Manual Swap: 150,062
1999 Sl2 4spd: 98,8xx

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Old 10-05-2018, 08:37 AM   #10
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Default Re: Timing Cover


...
1994 Sl2 5spd: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd Manual Swap: 150,062
1999 Sl2 4spd: 98,8xx

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Old 10-05-2018, 08:40 AM   #11
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Default Re: Timing Cover


...
1994 Sl2 5spd: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd Manual Swap: 150,062
1999 Sl2 4spd: 98,8xx

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Old 10-05-2018, 08:41 AM   #12
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Default Re: Timing Cover


...
1994 Sl2 5spd: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd Manual Swap: 150,062
1999 Sl2 4spd: 98,8xx

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Old 10-05-2018, 08:42 AM   #13
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Default Re: Timing Cover


...
1994 Sl2 5spd: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd Manual Swap: 150,062
1999 Sl2 4spd: 98,8xx

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Old 10-05-2018, 08:46 AM   #14
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Default Re: Timing Cover

The key thing with helicoils, or any tap job, is to turn the tap backwards frequently to break the chip. Oil is good too, only problem is you have to figure out how to clean out the hole when you are done.

...
Bryan Cotton
'99 SL2, 5SP bought new
Rebuilt at 204,067 September 2017
Engine, subframe, diff pin mod, brake lines, headliner, alternator, and so on!
'98 SC2, 5SP bought 2018

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Old 10-05-2018, 09:31 AM   #15
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Default Re: Timing Cover

Compressed air or brake cleaner that has a straw on it. IF the hole is completely stripped out you do not have to drill it out, just run in the helicoil tap.

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Old 10-05-2018, 10:12 AM   #16
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Default Re: Timing Cover

I am going to use compressed air then brake cleaner followed by more compressed air.
3/4 of the threads are completely gone, I will just run the drill to clean up the hole.
Hopefully it will work, or I am going to swap in my spare engine so I can properly and carefully repair this one and keep it as a backup.

...
1994 Sl2 5spd: 56,576 (Totaled 1/10/2018)
1995 Sl2 5spd Manual Swap: 150,062
1999 Sl2 4spd: 98,8xx

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Old 10-05-2018, 12:52 PM   #17
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Default Re: Timing Cover

If it is stripped out don't drill or you will end up with excessive clearance. If you want to clean it up use a smaller drill bit than the one provided. You will need a long shaft tap wrench as it MUST go in straight. You can not do it with just an open end wrench. This is a somewhat tricky repair. A socket, extension, and "T" handle adapter will work if careful.

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Old 10-05-2018, 07:36 PM   #18
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Default Re: Timing Cover

I drilled it out and fixed the threads. I guess the image hosting site is not working, so no pictures. Sorry.

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1995 Sl2 5spd Manual Swap: 150,062
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