Chevy S-10 Spark Plug hole repair

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John L. Wilkerson Jr. - 14 Sep 2004 16:09 GMT

Well... I did it. Cross-threaded an aluminum head by misaligning my
number 4 spark plug.

Threads are damaged to a moderate degree. I assume the threads towards
the bottom are fine. I managed to crank in a new plug, I had no
choice..... need the vehicle.

It runs *okay*, in other words, maybe slightly rougher idle, no engine
warning light... but with a *slight* oil leak. Nothing more than a
couple drops in the spark plug hole.

I am more or less content to leave it there forever if need be, BUT, I
don't like a vehicl that isn't right.

Can this bad boy be repaired without removing the head? I've done
research that says it can simply be fixed by using a thread chaser, and
greasing it up real good to catch any metal particles.

What is the proper procedure to use a thread chaser?

Also... IF the threads are too far gone, can a rethread be done without
head removal.... I want to cover all my bases.

Any advice?

Thanks!

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Steve B. - 14 Sep 2004 17:42 GMT

>It runs *okay*, in other words, maybe slightly rougher idle, no engine
>warning light... but with a *slight* oil leak. Nothing more than a
>couple drops in the spark plug hole.

A cross threaded plug doesnt cause an oil leak. If your leaking oil
its probably a bad valve cover gasket.

If you hadn't cranked the plug on in anyway then there was a small
chance that the thread chaser would have worked. At this point I
would try that first with no expectations that it was going to work.
Your probably looking at a helicoil at this point for the repair.
http://www.thetoolwarehouse.net/shop/HEL-5334-14.html (not necessarily
the size you need).

The worst thing that can happen at this point is that the threads are
not strong enough to hold the plug in and the plug blows out of the
head. If I were the only one driving it I would probably just leave
it be until next time I have to change the plugs. If anyone else had
to drive it that I would worry about then I would go ahead and fix it
properly.

Steve B.

>I am more or less content to leave it there forever if need be, BUT, I
>don't like a vehicl that isn't right.
[quoted text clipped - 11 lines]
>
>Thanks!

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John L. Wilkerson Jr. - 14 Sep 2004 19:57 GMT

> The worst thing that can happen at this point is that the threads are
> not strong enough to hold the plug in and the plug blows out of the
> head. If I were the only one driving it I would probably just leave
> it be until next time I have to change the plugs. If anyone else had
> to drive it that I would worry about then I would go ahead and fix it
> properly.

OK.... thanks. I figure if the plug is launched, then I'll look at further
action. I think I can be content to leave things alone.

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GMC Gremlin - 16 Sep 2004 00:28 GMT

Heli-coils are supposed to be stronger than the normal threads (in aluminum
at least?)

GMC Gremlin

> > The worst thing that can happen at this point is that the threads are
> > not strong enough to hold the plug in and the plug blows out of the
[quoted text clipped - 5 lines]
> OK.... thanks. I figure if the plug is launched, then I'll look at further
> action. I think I can be content to leave things alone.

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