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Trans. bolt stripped...... How to fix?

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I am one of the unluckiest people at certain times, and since the first of the year I have been getting my lunch handed to me by my 04 450. First it was the clutch, inner hub(2), the inner hub is a scary story, for another day maybe, water pump seal, and now Im pretty sure the Tranny bolt is gone, it got cross threaded along time ago and has been fine, but tonight I felt that fatal slipping on the last little turn.

Splitting the cases to fix this is going to drive me crazy, is that the only way to fix it????????????????????????????????????????????????? :cry::cry:

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You will have to split the cases to fix it right.

I would first try running a tap in there and trying to clean up the threads. You will need an extended length tap to reach the threads. Throttlejockey has one, maybe you can borrow his, or he can at least tell you where you can buy one.

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use a time cert. MOST SHOPS HAVE THEM READILY AVAILABLE I STRIPPED OUT MY VALVE COVER BOLT THEY FIXED IT NO PROBLEM FOR ABOUT $120.00 THEY HAD TO CHARGE ME THAT MUCH BECAUSE IT TAKES 1 HOUR OF SHOP TIME TO DO IT AND THAT WAS THERE LABOR RATE

AT LEAST YOU WONT HAVE TO PULL THE CASES

HOPE THIS HELPS :cry:

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You can't fix that thread w/o splitting the cases. You could use a slightly longer bolt after cleaning out the threads with a tap.

If you need a tap BK let me know and I'll send you one you can use.

I think the 450 is the same as the 250, so if it is, that hole comes out behind the clutch basket. You could blow out the chips through that hole if you pull the clutch cover. (the inner one)

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I knew that was going to be the answer, I was hoping someone had some up with a fix other than that. i will try the longer bolt thing after trying the tap.

TJ, I will try to locate one locally thats long enough. How long is the one you have, along with size and thread count? I appreciate the offer, and if I cant find one I'll shoot you a PM. Im going to ride once this week, then Im out of town for a long weekend in Michigan, then I'll deal with it when I get back :cry::cry:

I guess its time for me to learn how to split the cases on my fourfiveooooooo.... :cry:

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I purchased an allen head 3/8" course thread from the hardware. Using a good flashlight/droplight and a probe, measure the depth of the left case,(smooth no thread part). With this measurment, use a well greased drill bit to over size the left case so it will accept the shank of the new 3/8" bolt, and a 3/8" course tap. Then dpending on how stripped the threads are, use the recomended bit for the 3/8" tap to drill the threaded right side of the case, or just thread it if it is really bored out. Make sure everything is greased, and nice and straight!! I put a fiber washer on the allen head bolt with a dap of R.T.V. at each change and have not had a problem since. I know it sounds scary, but there is actually a lot of "meat There, and the 3/8" course was about the next size that would cut thread.

B.T.W. used cheapo ATF to flush well after the job.

Again I know this might freak the purist and I am not saying "just do it" because I don't know how comfortable you are with this stuff. Just saying it worked great for me. :cry:

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I stripped my tranny drain bolt as well and it came back to life with a long tap. Throttlejockey offered to send me his but I just thought I'd buy one here in Canada to avoid having to deal with the border both ways. When I priced it out I nearly crapped myself, the only one I could find was nearly 160 dollars Canadian. I went and bought a tap and had a five inch extension silver soldiered in the middle. It worked like a charm and I no longer have to change my oil by removing the clutch cover.

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Use a magnetic screwdriver to get the shavings out, and order a new top subframe bolt. the one that goes in near the top of the shock, it worked like a charm for me. I tried to get the bolt locally, I bought five and none would work. Run three or four quarts of cheap oil though it without starting it to flush out any large shavings.

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Blowing the chips out from the clutch side while tapping is not such a good idea because there is a sizeable gap between the case halves for the chips to escape into the tranny cavity. Rather, a good vacuum source (shop vac necked down to a small hose), will draw them out the clutch side nicely. Oversizing the hole to use an american thread is a great idea. A helicoil will require disassembly I'm afraid. Good Luck!

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The size is M8x1.25 6" long.

I didn't realize there was an air space between the 2 halves. I don't remember seeing that on the 250.

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I was thinking about this last night, is there enough material to just tap the case where the bolt goes in on the left side? Then I would have a setup like most MFG's use, instead of a 5" long bolt going all the way through the motor??

Now since there is a gap in between the cases, would this cause a problem? If I can get away with re-tapping the threads and cleaning it by pulling the right side cover, that doesnt sound all that bad, a small hassle compared to the alternative.

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was thinking about this last night, is there enough material to just tap the case where the bolt goes in on the left side?

I don't know about that. That bolt actually holds the cases together too.

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well, there went that idea.

TJ, did you just re-tap after you had a problem? Im a little concerned with getting all the metal out of there, but I think I could rig up something with my shop vac to get most of the stuff out.

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Actually, I never had a problem but snagged a few taps from work just in case.

I did lend them out to a few guys and they had good results.

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ok, thanks for the help. Ive got a friend that works at the air base, I'll see if he can borrow a tap of those measurements for me, if that doesnt work I'll roll up my sleeves and take the beast apart.

thanks again for all the tips everyone.

Brian

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