2005 Pontiac Sunfire AutomaticFACTORY OEM SERVICE PROCEDURE

General Thread Repair

Tools RequiredΒ 

J 42385-850Β  Thread Repair Kit. See Special ToolsΒ .

Fig 1: View Of Bushing Type Insert & Base Material
GM320675Courtesy of GENERAL MOTORS CORP.

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert (1). During the bushing installation process, the driver tool expands the bottom external threads of the insert into the base material (2). This action mechanically locks the insert in place. Also, when installed to the proper depth, the flange of the insert will be seated against the counterbore of the repaired hole.

    Fig 2: Drilling & Tapping Threads
    GM320670Courtesy of GENERAL MOTORS CORP.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • β€’ You smell fuel, burning insulation, or see smoke.
  • β€’ Brakes feel soft, pull hard to one side, or make grinding noises.
  • β€’ The engine overheats, stalls repeatedly, or misfires under load.
  • β€’ You are missing required tools, torque specs, or safe lifting equipment.
  • β€’ You are not confident in the next step or safety outcome.