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Old 08-07-2014, 09:21 PM   #1 (permalink)
turbovanman
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How to repair broken starter bolts like OEM.

I am working on a 95 for the last few days, had to pull the engine out to do the head gaskets, flexplate was chewed up due to numerous butchered starter repairs by other shops. Long story short, had a leaking headgasket and it kept hydrolocking and blowing the starters off. The bolts were repaired but not properly as half were still in the block and the helicoils were flush with the flange, which won't let the shoulder of the bolt do its job so the starter doesn't move.

So 3 hours later, I had it fixed so I think, I removed the helicoils, drilled out the remaining bolts and retapped for helicoils. Also didn't know the last shop broke off a friggin drill bit, Now, the downside is the block hole is much larger so the knurled shoulder of the bolt is loose, this will let the starter become loose over time. My fix, the helicoils sit deep in the block, aprox 1/2-3/4 of an inch, I measured the protusion thru the starter. I then took a drill bits up to 1/2" and drilled up to the helicoil. I then took some 3/8 course nuts and drilled out the centers to match the knurl, then ground down the outside until they were a tight fit into the block and voila, a factory repair. Now the bolts fit snugly just like OE.

See pictures below in post #7.

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2004 VW Wagon TDI 5 speed-blue-also modified-Mine!

1989 Dodge Caravan ex daily driver, 2.5L TIII DOHC Turbo, GT35R, [email protected] mph.

2002 Gold Dmax 4 door, 2500HD 4x4-new camper/trailer hauler-minor mods and a small tow tune!

Last edited by Tom S.; 08-08-2014 at 05:42 AM.
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Old 08-07-2014, 09:28 PM   #2 (permalink)
dieselmike1
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Now that's pretty ingenious!

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Old 08-07-2014, 09:42 PM   #3 (permalink)
Freddyack
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Quote:
Originally Posted by turbovanman View Post
I am working on a 95 for the last few days, had to pull the engine out to do the head gaskets, flexplate was chewed up due to numerous butchered starter repairs by other shops. Long story short, had a leaking headgasket and it kept hydrolocking and blowing the starters off. The bolts were repaired but not properly as half were still in the block and the helicoils were flush with the flange, which won't let the shoulder of the bolt do its job so the starter doesn't move.

So 3 hours later, I had it fixed so I think, I removed the helicoils, drilled out the remaining bolts and retapped for helicoils. Also didn't know the last shop broke off a friggin drill bit, Now, the downside is the block hole is much larger so the knurled shoulder of the bolt is loose, this will let the starter become loose over time. My fix, the helicoils sit deep in the block, aprox 1/2-3/4 of an inch, I measured the protusion thru the starter. I then took a drill bits up to 1/2" and drilled up to the helicoil. I then took some 3/8 course nuts and drilled out the centers to match the knurl, then ground down the outside until they were a tight fit into the block and voila, a factory repair. Now the bolts fit snugly just like OE.

I'll post the pics later.
WOW!
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Old 08-07-2014, 10:24 PM   #4 (permalink)
turbovanman
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Just trying to start her and she sounds great but won't light,
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1984 G20 Diesel Get a Way Van, 6.2L turbo. Rebuilt 1989 700R4, 3.08 gears. Fluidamper, modified hummer headers, 2.5" mandrel Y-pipe to 3 inch single system, Hooker Max Flo muffler, 3 inch F350 mandrel bent tailpipe-passenger side exit, 6.5L turbo lower intake, 6.5 military IP-5149, Turbonator open faced injectors set to 2500 psi, HX35W with a 60x86mm cast wheel at 15psi, ARP studs, .010" head gaskets, bypass oil system, Dmax van fuel pump/filter combo, Aeromotive fuel pump. REMOTE MOUNT TURBO INSTALLED!!!! Burning hydraulic fluid, jet fuel, WMO.
2003 VW Wagon 2.0L TDI auto, silver, heavily modified-Wife's.
2004 VW Wagon TDI 5 speed-blue-also modified-Mine!

1989 Dodge Caravan ex daily driver, 2.5L TIII DOHC Turbo, GT35R, [email protected] mph.

2002 Gold Dmax 4 door, 2500HD 4x4-new camper/trailer hauler-minor mods and a small tow tune!
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Old 08-07-2014, 10:35 PM   #5 (permalink)
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I've read[never done it myself] that you can convert to 3/8 starter bolts if the holes aren't too boogered up.
I would recommend a heavy duty home made front brace. I've seen plenty of the light weight stock GM braces break. I make my own heavy duty ones to clear a second frost plug heater on the passenger side.
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Old 08-07-2014, 11:41 PM   #6 (permalink)
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Quote:
Originally Posted by turbovanman View Post
I then took some 3/8 course nuts and drilled out the centers to match the knurl, then ground down the outside until they were a tight fit into the block and voila, a factory repair. Now the bolts fit snugly just like OE.
Dang, If you had a lathe and some JB Weld you would be awesome.

So how does this go, drill to match, grind to fit and hammer in to size.
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Old 08-08-2014, 03:36 AM   #7 (permalink)
turbovanman
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Ok, pics as promised. Maybe a mod can put them in my first post? Thanks.

That's how I got it and if you look at the ring gear, you can see some of the teeth are really thin.

BTW Diesel Pro, I had to use some cold weld and a threaded plug, ahem to fix a hole I made,















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1984 G20 Diesel Get a Way Van, 6.2L turbo. Rebuilt 1989 700R4, 3.08 gears. Fluidamper, modified hummer headers, 2.5" mandrel Y-pipe to 3 inch single system, Hooker Max Flo muffler, 3 inch F350 mandrel bent tailpipe-passenger side exit, 6.5L turbo lower intake, 6.5 military IP-5149, Turbonator open faced injectors set to 2500 psi, HX35W with a 60x86mm cast wheel at 15psi, ARP studs, .010" head gaskets, bypass oil system, Dmax van fuel pump/filter combo, Aeromotive fuel pump. REMOTE MOUNT TURBO INSTALLED!!!! Burning hydraulic fluid, jet fuel, WMO.
2003 VW Wagon 2.0L TDI auto, silver, heavily modified-Wife's.
2004 VW Wagon TDI 5 speed-blue-also modified-Mine!

1989 Dodge Caravan ex daily driver, 2.5L TIII DOHC Turbo, GT35R, [email protected] mph.

2002 Gold Dmax 4 door, 2500HD 4x4-new camper/trailer hauler-minor mods and a small tow tune!

Last edited by turbovanman; 08-08-2014 at 03:39 AM.
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Old 08-08-2014, 05:45 AM   #8 (permalink)
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Instead of moving the pictures to your original post, I edited the post to point out the pictures could be found below.

You were very ingenious in finding a way of fixing what others had screwed up. I bet getting the drill bit out was fun.
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Old 08-08-2014, 11:57 AM   #9 (permalink)
turbovanman
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Quote:
Originally Posted by Tom S. View Post
Instead of moving the pictures to your original post, I edited the post to point out the pictures could be found below.

You were very ingenious in finding a way of fixing what others had screwed up. I bet getting the drill bit out was fun.
Thanks.

Yeah, was a bit of a challenge but Snap On skinny die grinder bits sure help in these situations,
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1984 G20 Diesel Get a Way Van, 6.2L turbo. Rebuilt 1989 700R4, 3.08 gears. Fluidamper, modified hummer headers, 2.5" mandrel Y-pipe to 3 inch single system, Hooker Max Flo muffler, 3 inch F350 mandrel bent tailpipe-passenger side exit, 6.5L turbo lower intake, 6.5 military IP-5149, Turbonator open faced injectors set to 2500 psi, HX35W with a 60x86mm cast wheel at 15psi, ARP studs, .010" head gaskets, bypass oil system, Dmax van fuel pump/filter combo, Aeromotive fuel pump. REMOTE MOUNT TURBO INSTALLED!!!! Burning hydraulic fluid, jet fuel, WMO.
2003 VW Wagon 2.0L TDI auto, silver, heavily modified-Wife's.
2004 VW Wagon TDI 5 speed-blue-also modified-Mine!

1989 Dodge Caravan ex daily driver, 2.5L TIII DOHC Turbo, GT35R, [email protected] mph.

2002 Gold Dmax 4 door, 2500HD 4x4-new camper/trailer hauler-minor mods and a small tow tune!
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