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Intake manifold retap help

AppleJacks

New Member
Joined
Aug 30, 2025
Messages
12
Hello, hope everyone is doing well. Last night I rebuilt my carb and while putting it back on one of the studs from my intake popped and was spinning freely. Just wanted to know if anyone has had a similar experience and what they had done to fix it. Is it possible to retap the hole or does it make more sense to get a whole new intake? Sorry if this is a poor explanation. Would appreciate any help. Thanks!
 

ntsqd

heratic car camper
Joined
Jan 30, 2005
Messages
5,953
Loc.
Upper SoKA
Like this: 5/16-18 Helicoil Kit. When dealing with studs it is crucial that the new threads be straight (orthogonal to the gasket surface). If you have any doubt at all about your ability to drill the hole straight I'll suggest using something like one of these drill blocks.
Like others have said, drill out the hole with the provided drill bit. Do not drill the hole any deeper! Use the special tap to tap the new hole. Use the odd tool to install the threaded insert. Re-install the stud.
 

Apogee

Contributor
Bronco Guru
Joined
Nov 26, 2005
Messages
6,345
Loc.
Tangent, OR
Heli-Coil kits are great, but do require a specific drill and tap to machine the new threads for the insert, so they can be more expensive per insert than some of the other options that use standard tooling. That said, there's almost nothing lower-profile than a Heli-Coil, so for tight spaces without a lot of material around the threads, these are sometimes the only solution.

That said, I just repaired an aluminum fixture plate for my milling machine and used some over-the-counter E-Z Lok inserts, as they used a standard drill/tap for the OD thread on the insert itself, which saved me both time and money in fixing it. They offer both steel (12L14) and stainless steel (304) versions in most sizes, and I'm pretty sure I got mine off Amazon the next day.

Another option with a more positive, keyed locking solution would be a Keensert/Recoil type thread insert, where these can work well in higher vibration applications, lower strength base materials, etc.
 

ntsqd

heratic car camper
Joined
Jan 30, 2005
Messages
5,953
Loc.
Upper SoKA
I debated mentioning those options and decided to keep it simple with just the Helicoils because I suspect that they're the most likely to fit and work. Without pictures I'm fearing that the boss around the stud's threaded hole is not very large.
 

nvrstuk

Contributor
Just a Bronco driver for over 50 yrs!
Joined
Jul 31, 2001
Messages
10,606
Loc.
PNW
Tape that manifold with some good tape. You don't want any drill chips or filings down there. What Bowsher said
 
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