Thread Repair - Suzuki XL7 2007 Service Manual

Thread Repair

Special tool
J 42385-700 High Feature Thread Repair Kit
J 42385-2000 Thread Insert Kit
J 43965 Thread Repair Extension Kit
The thread repair process involves a solid, thin walled,
self-locking, carbon steel, bushing type insert. During the
insert installation process, the installation driver tool
cold-rolls the bottom internal threads and expands the
bottom external threads of the insert into the base
material. This action mechanically locks the insert into
place.
The drill bit and counter bore tool from the tool kit J
42385-700 and J 42385-2000 is designed for use with
either a suitable tap wrench or drill motor. Limited access
and larger hole repair may process better using a tap
wrench. An extension from kit J 43965 may also be
necessary to drive the thread repair tooling dependent
on access to the hole being repaired. Use only a tap
wrench when tapping the hole and during installation of
the insert.
It is critical that the drilling, counterboring and tapping of
the hole to be repaired follows the same centerline as
the original hole.
During the drilling and tapping of the hole being repaired
ensure the tooling is consistently machining
perpendicular to the surface of the base material.
If the threaded hole being repaired has a base surface
perpendicular to the hole centerline, tapping guides are
available to aid in tapping the hole.
Tap Tap Tape
Size Guide Size
— J 42385- —
6 x 1.0 729 10 x 1.5
8 x 1.25 730 12 x 1.5
Engine Mechanical: 1D-221
Tape Tap Tape
Guide Size Guide
J 42385- — J 42385-
731 14 x 1.5 736
732 20 x 1.5 737