Stripped Sway Bar Frame Bolt Hole Thread Fix

[JZ57_CN]

To those who have stripped thread on the frame for front sway bar bushing bolt, this repairing could help you solving the problem.

On my 1999 Tahoe 2WD, 4Dr, the front driver-side sway bar bushing is directly bolted on the frame with 2 self-taping bolts. Some time bolt cold strip the thread on the frame if over-torque happens.

The solution is either using over-size bolt or adding a nut to the bolt. But the over-size bolt may have larger hex-head, the fixed distance between 2 holes and bushing bracket does not have enough space for larger head bolt. So, add a nut to the bolt is more realistic. The front frame is box type, no accessing hole. So, you need drill a 1-1/4 diameter hole on the side of the front frame near bushing bracket bolt. See the picture.

Fig.1: Accessing holes:



If the stripped thread happens on passenger-side, drill ONE hole on side of the frame between 2 holes.

Some Chevy B-body forum members weld a insert nut to the hole, but you need some weld equipment which costs you more.

Here is list of tool and parts you need:

1) Electric drill
2) 1/8 drill bit
3) 1-1/4 (maximum) step drill bit
4) Grind stone
5) 3/8 ratchet
6) 8MM or 5/16 Allen wrench (3/8 drive)
7) 14MM or 9/16 box wrench
8) Needle nose pliers
9) 3/8-16X1.5 socket head bolt, 3/8-16 nut

Fig.2 Tools:



The Chinese-made $12 step drill bit was purchased from Amazon.com, but its quality is good enough to get job done.

Fig.3 Step Drill bit:



Procedure:

Remove the front wheel.

Attach a pieces of masking tape between power steering gear attaching bolts, mark a drilling spot.

Fig.4 Marking Spot:



Use a 1/8 drill drilling a pilot hole first, then use step drill bit continuing the job. The step drill bit needs some cooling while doing the job, so spray some WD-40 every minute.

After the accessing hole diameter is large enough for a 14MM box wrench accessing, then use a grind stone attaching to electric drill to chamfer sharp edge one the accessing hole.

Fig.5 Hole diameter:



To engage the nut on the bolt is a challenge job, be patient! Since the accessing hole is NOT larger enough for 2 fingers, so you need a needle nose pliers as a helper. What I did was using masking tap wrapping the nut on A finger tip, then punch a hole on masking tap to expose thread, then using ONE finger to put the nut on the top of bolt while the bolt was turning with an Allen wrench.

Fig.6 Finger & nut:




Finally, tighten the bolt and nut with box wrench and Allen wrench.

Fig.7 Final:

[NEUMANNZZ]

I have had that happen before, using a bigger self tapping bolt worked for a while then finally used a nut and bolt to do it. good writeup!!!

[ragmc]

Graet write up!!!!!!

[tonxcab]

Good write up does this happen alot.

[intimidator4x4]

Happened on mine 4 years ago, that is how I did it, worked good