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This website uses cookies to improve your experience. By continuing to use thebonnevilleshop. Please also read our Privacy Policy on how we handle any personal data. Close Privacy Overview This website uses cookies to improve your experience while you navigate through the website. Getting in a rush installing spark plugs can easily lead to cross-threading a plug, resulting in stripped or severely damaged threads in the cylinder head.
When that happens, your quick tune-up can suddenly turn into a major job. Welding and retapping requires — at the very least — top end disassembly. But depending on your mechanical ability and the ease with which you can access the spark plug holes, you might be able to tackle installing a thread insert yourself, and without having to tear the engine down. We know that some people wince at the idea of inserts of any kind, but practical experience has proven them to be a secure, permanent fix for stripped spark plug threads.
A nice survivor currently receiving a little freshening up, it had spark plug threads so worn they would barely hold a plug. There are a number of different spark plug rethread kits on the market. It is, in fact, a straightforward job, but it does come with a bit of a pucker factor: Cutting new threads presents the very real risk of introducing metal swarf into the cylinder. As with any project, the key to success is patience. Before you begin, remove the old plugs and then roll the engine over until the piston for the offending plug is at the top of its stroke at top dead center so the valves will be closed.
Depending on how close the piston comes to the plug hole, you may want to spin the engine a bit more so the piston is farther down in the cylinder. Although you can still see the threads, close inspection shows them to be damaged and very worn out, allowing the plugs to loosen up and wobble, making the problem worse.
After ensuring the cylinder is at top dead center so the valves are closed, gently stuff a grease-soaked rag into the cylinder cavity. Use a single piece, and avoid packing it in place. Next, liberally coat the rethreading tool with grease and thread it into the plug hole as far as it will go just using hand pressure. The original threads will help guide the tool. Check your work and clean it off. This is what our spark plug hole looked like after our first, tentative cut. The old threads have been chased and the tool is cutting them out as it works down, subsequently cutting a new, larger set of threads for the insert that will replace the bad threads.
This is what our first plug hole looked like after our second run with the rethreading tool. We had stopped just short of fully rethreading the plug hole to check our work. Between cuts, clean and then liberally reapply grease to the threading tool. Reinstall it in the plug hole and continue cutting new threads.
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