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HOMESERVICE MANUALSOLDSMOBILE2004BRAVADA AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1440 (ENGINE MECHANICAL - 5.3L)REPAIR INSTRUCTIONSOFF-VEHICLE REPAIR INSTRUCTIONSTHREAD REPAIRMAIN CAP BOLT HOLE THREAD REPAIR
2004 Oldsmobile Bravada AWD

Main Cap Bolt Hole Thread Repair

2004 Oldsmobile Bravada AWDSECTION Main Cap Bolt Hole Thread Repair
WARNING: This page is about a different car, the 2003 GMC Envoy XL and 2003 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. The main cap bolt hole thread repair kit consists of the following items:
    • The drill (1)
    • The tap (2)
    • The installer (3)
    • The fixture plate (4)
    • The long bolts (5)
    • The short bolts (6)
    • The alignment pin (7)
    • The bushing (8)
      Fig 1: Identifying Main Cap Bolt Hole Thread Repair Kit Items
      G02129593Courtesy of GENERAL MOTORS CORP.
  2. Install the fixture plate, bolt, and bushing, onto the engine block.

    Position the fixture plate and bushing over the hole that is to be repaired.

  3. Position the alignment pin in the desired hole and tighten the fixture retaining bolts.
    Fig 2: Installing Fixture Plate, Bolt, And Bushing Onto Engine Block
    G02129594Courtesy of GENERAL MOTORS CORP.
  4. Drill out the damaged hole.

    The outer bolt hole locations 11-20 have the shallower counterbores. Use sleeve J 42385-316 with the drill.

    Drill until the stop collar of the drill bit or the sleeve contacts the bushing.

  5. Using compressed air, clean out any chips.
    Fig 3: Drilling Out Damaged Hole
    G02129595Courtesy of GENERAL MOTORS CORP.
  6. Using a tap wrench, tap the threads of the drilled hole.

    In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark on the tap aligns with the top of the bushing.

    For the deeper main cap holes 1-10, rotate the tap until the upper mark (4) on the tap aligns with the top of the bushing (3).

    For the shallower main cap holes 11-20, rotate the tap until the lower mark (1) on the tap aligns with top of the bushing (3).

  7. Using compressed air, clean out any chips.
  8. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463) or equivalent into the hole.
  9. Using compressed air, clean any cutting oil and chips out of the hole.
    Fig 4: Tapping Threads Of Drilled Hole Using Tap Wrench
    G02129596Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

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

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