DupermanDave

So after months and months of chasing down my vacuum leak trying to fix my "idle daemon" I have finally fixed everything. One last thing remained to fix the check engine light. I must clean or replace the EGR valve. So I bought all the stuff to clean the EGR...long story short the EGR is now clean, the truck runs nicely, and the CEL has been gone for a week now.

One thing happened, though. The EGR temperature sensor piece on the back of the throttle body now has stripped threads. I replaced the bolts hoping they were the problem, but to no avail. The threads are stripped. I have everything fixed and it's okay to drive. The bolts are on tight enough to prevent a vacuum leak. But it's still a problem.

I've been wanting to try heli coils a second time since my last experience, but I still don't feel up to the task to do it myself. Is there any other way to fix striped threads? Solder? I saw a permatex stripped thread kit that uses an epoxy resin and a non-stick grease that keeps the bolts from sticking to the epoxy as it dries. Would this be a viable alternative?

The real problem is, I don't want to remove the intake plenum AGAIN and risk stripping or damaging anything else. I've gotten everything nice. But I can't leave those threads like that. If I go the heli coil route, I'll need to buy more RTV for the intake gasket, a drill bit set and a thread repair kit, so the total project will be $40+, not to mention the truck's downtime. It's my daily driver. I know it's a job that should take 5 minutes, but as I said, I havent had luck in the past when I used the heli coil. They just tore apart in the hole.

Are there any other alternatives? Something I can do with the plenum in place?

Tragic Drive

Can you use a tap to the next size up?

DupermanDave

I could try that, but is that worth it? Do they sell tap kits for the next size up that can be done in that 4 inch space?

yoterr

i bought my tap n die set for 30 bucks at advance, but it might be hard to do in a cramped space...but IMO best $30 dollar tool set ive bought yet, ive replaced like 15 bolt in misc places including my tanny x member