Miss-threaded the top hole for a top starter bolt

[Markopolo]

I changed the starter on my SW2 98 and somehow I miss-threaded the top hole for the top bolt. I was able to tighten the bolt only about 1/3 of its way. I feel the thread will be stripped off if I screw it fully. The bottom bolt and the partially screwed top bolts are holding the starter for now.
I am not sure what would be the best way to fix the internal thread in such a narrow place. Do I need to fix the thread by using the tap 8mm x1.25 or will it strip the thread? Or do I need to replace my old thread with a thread insert? How hard would that be to do in such a tight place? Has anyone had the same kind of problem? Does any one have a better idea?
I was also thinking to put in some sort of studs instead of the bolt. I read somewhere on the forum that someone did it. What kind of studs did they use? Where would I get them?

[bumpdraft]

Shadetree mechanic here, who’s cross-threaded more bolts than I care to admit.

1.25mm pitch is coarse. If you cross-threaded, the bolt went in at an angle and the original aluminum threads are probably still there. Maybe you can “find” the good threads by pushing the bolt up against the hole and turn it very slowly backwards, until you feel it drop into a thread. Use a socket and extension without the ratchet. I always wire wheel bolts before I reinstall them (I’m neurotic). – check that it’s perfectly clean and sharp.

I’d remove the starter so you could see. Hopefully, you’re not lying on your back in the snow.
If I was desperate enough (and believe me, I would be!) I’d try removing the top motor mount and whatever else you’d have to do so you could rock the engine forward to make more room.

Maybe by the time you move the engine forward getting a tap in there will not be so difficult.

My favorite quote from Yoda: “Do, or do not. There is no ‘try’.”

[Low Saturn]

Once you get the threads fixed. Install studs instead of using those bolts. Makes installation way easier. I use the same studs that are used for the intake and exhaust manifolds.

Tighten the studs to the block, slide on the starter then reach up and give the nuts a few turns by hand. Then tighten the nuts all the way. Doing it this way makes sure you dont cross thread a bolt you cant see, the starter is supported by the studs during installation, and the starter is properly alligned during installation.

[asdf]

That's a good idea. I wonder why the starter bolts look so unique though...

[Low Saturn]

Originally Posted by bmxgoof

That's a good idea. I wonder why the starter bolts look so unique though...

??????

[asdf]

Don't they have like a little pointed nose on the end, and a low profile head? And are class 10.9. Maybe I'm thinking of something else, but they don't look even close to any other bolts on the car.

[Low Saturn]

Originally Posted by bmxgoof

Don't they have like a little pointed nose on the end, and a low profile head?

Not the ones I've removed. Just regular bolts like on 90% of the car.

[Markopolo]

I don't have any the intake and exhaust manifolds studs. Where would I get them? Do Autozone, Checker or Napa have them or not?

[Low Saturn]

They might. You could go to the dealer too. I just have a bin full from all the Saturns I've taken apart.

You'll need two studs and two nuts.

[Markopolo]

What is a total length of these studs? What is a threaded lenght of the part that goes into the hole?

[Low Saturn]

Originally Posted by Markopolo

What is a total length of these studs? What is a threaded lenght of the part that goes into the hole?

I'll check when I get home from work.

[Low Saturn]

Originally Posted by Markopolo

What is a total length of these studs? What is a threaded lenght of the part that goes into the hole?

The shorter threaded portion is 5/8" long, the longer threaded portion is 1" long. The 5/8" long side is what you would thread onto the block.

[Markopolo]

Originally Posted by Low Saturn

The shorter threaded portion is 5/8" long, the longer threaded portion is 1" long. The 5/8" long side is what you would thread onto the block.

I had to order exhaust manifold studs from Saturn dealership for my SW2 98 engine. These studs are shorter than yours studs. They have a shorter threaded portion is 5/8" long, the longer threaded portion is about 5/8 or 6/8” long. I think they might be too short to put on. Does anyone know what Saturn engine (model and year) has longer studs? And what kind of studs are they?

[Low Saturn]

I believe the intake manifold uses longer studs than the exhaust manifold.

[Markopolo]

Originally Posted by Low Saturn

I believe the intake manifold uses longer studs than the exhaust manifold.

Do you know all studs the same length on different Saturn engines?

[Low Saturn]

Exhaust manifold studs are the same from 1991-2002. Intake manifold studs are the same from 1991 to at least 1999. Cant say for sure once they changed to the plastic intake manifold.

I can get part numbers once I get home.

[Markopolo]

Originally Posted by Low Saturn

Exhaust manifold studs are the same from 1991-2002. Intake manifold studs are the same from 1991 to at least 1999. Cant say for sure once they changed to the plastic intake manifold.

I can get part numbers once I get home.

It would be nice if you could give me a part numbers of your studs (or at least an engine model and year) then I could oder them from my dealership.
Thank you.

[Low Saturn]

Originally Posted by Markopolo

It would be nice if you could give me a part numbers of your studs (or at least an engine model and year) then I could oder them from my dealership.
Thank you.

Actually the intake and exhaust manifold mounting studs are the same:
p/n 21006951 (1991-2002)

The exhaust manifold to downpipe are the shorter ones.
p/n 21006166 (1991-2002)

[dgrant09]

I appreciate the info and will be watching this thread.
We did the same mistake three weeks ago and still have to do a fix!
We replaced the starter with -5 degrees f, my back in the snow, that was cold. Fortunately, I had my truck to jump in every 10 minutes or so to warm up..
Thanks all for the thread repair info!!

[Markopolo]

Originally Posted by Low Saturn

Actually the intake and exhaust manifold mounting studs are the same:
p/n 21006951 (1991-2002)

The exhaust manifold to downpipe are the shorter ones.
p/n 21006166 (1991-2002)

Thank you for this info. I got a wrong stud. My stud is p/n 21006166. Yes, it's a shorter one. I need another one. Thanks again.