Automotive Technology Principles,
Sixth Edition Diagnosis, and Service
Chapter 8
Fasteners and
Thread Repair
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LEARNING OBJECTIVES (1 of 2)
8.1 Identify bolts and explain the strength ratings of
threaded fasteners.
8.2 Discuss the purpose of nuts, taps, dies, thread
pitch gauges, screws, and washers.
8.3 Discuss how snap rings and clips are used.
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LEARNING OBJECTIVES (2 of 2)
8.4 Explain how to avoid broken fasteners.
8.5 Compare the different types of thread repair
inserts.
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THREADED FASTENERS ( 1of 2)
• Cap Screws
– Fastener that is threaded into a casting.
• Technician refers to as a bolt.
• Stud
– A short rod with threads on both ends.
• Crest
– Outside edge of the threads where a
measurement is made.
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Figure 8.1 The dimensions of a typical bolt
showing where sizes are measured. The major
diameter is called the crest
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Animation: Bolt Size Dimensions
(The animation will automatically start in a few seconds)
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THREADED FASTENERS (2 of 2)
• Fraction Threads
– Measured Unified National Course
– Measured Unified National Fine
• Pitch
– Standard combinations of sizes and numbers
of threads per inch.
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Figure 8.2 Thread pitch gauge used to measure the
pitch of the thread. This bolt has 13 threads to the
inch
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Animation: Bolt Size Dimensions
(The animation will automatically start in a few seconds)
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Figure 8.3 Bolts and screws have many different
heads which determine what tool must be used
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Chart 8.1 The American national system is one
method of sizing fasteners.
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METRIC BOLTS
• Identified my the “M” designation
• Diameter in millimeters (mm) across the crest
• The distance in millimeters between the threads
(pitch)
• Example: M8 X 1.5
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QUESTION 1: ?
What is the difference between a bolt
and a stud?
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ANSWER 1:
A stud is a short rod with threads on
both ends.
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GRADES OF BOLTS
• The strength or classification of the bolt.
• Bolt heads are marked to indicate grade.
• Metric bolts have a decimal number to indicate
grade.
• Higher grades have threads that are rolled instead
of cut.
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Figure 8.4 The metric system specifies fasteners
by diameter, length, and pitch
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Figure 8.5 Stronger threads are created by cold-rolling a
heat-treated bolt blank instead of cutting the threads
using a die
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TECH TIP
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Animation: Bolt Threads
(The animation will automatically start in a few seconds)
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TENSILE STRENGTH
• The maximum stress under tension (lengthwise
force) without causing a failure.
• Specified in pounds per square inch (PSI)
• Fractional fasteners use raised marks on head
to identify tensile strength.
• Metric fasteners use a number to idicate
property class.
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Figure 8.6 Metric bolt (cap screw) grade
markings and approximate tensile strength
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SAE bolt tensile strength designations.
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QUESTION 2: ?
What is meant by the grade of a
threaded fastener?
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ANSWER 2:
The strength or classification of the
bolt.
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NUTS
• Used on cap screws.
• Metric nuts marked with dimples to show strength.
• Some use interference fit to hold torque.
• May be coupled with a washer to hold torque.
• Some nuts require the use of thread locker.
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Figure 8.7 Types of lock nuts. On the left, a nylon ring;
and the other two use a distorted shape to keep the nut
from loosening
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TAP AND DIES
• Taps are used to cut threads in holes.
• Dies are used to cut threads on round studs or
rods.
• Fractional and metric sizes
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Figure 8.8 A typical bottoming tap used to create
threads in holes that are not open, but stop in a casting,
such as an engine block
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Figure 8.9 Many taps, especially larger ones,
have the tap drill size printed on the top
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Figure 8.10 A die is used to cut threads on a
metal rod
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Figure 8.11 (a) A T-handle is used to hold and rotate
small taps. (b) A tap wrench is used to hold and drive
larger taps
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THREAD PITCH GAUGE
• A hand tool with the thread pitch on a blade.
• Used to determine the thread pitch of a fastener.
• Metric and fractional tools.
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Figure 8.13 A typical metric thread pitch gauge
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FREQUENTLY ASKED QUESTION
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Figure 8.14 A thread chaser is shown at the top
compared to a tap on the bottom. A thread chaser is
used to clean threads without removing metal
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Sheet Metal Screws
• Fully threaded screws with a point.
• Sometimes referred to as “self tapping”.
• Used in fenders, trim and door trim panels.
• Sized according to their major thread diameter.
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Figure 8.15 Sheet metal screws come with many
head types
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Fractional screw sizes
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Figure 8.16 Various types of nuts (top) and washers
(bottom) serve different purposes and all are used to
secure bolts or cap screws
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Figure 8.17 Some different types of snap rings. An internal snap ring fits
inside of a housing or bore, into a groove. An external snap ring fits into a
groove on the outside of a shaft or axle. An E-clip fits into a groove in the
outside of a shaft. A C-clip shown is used to retain a window regulator
handle on its shaft
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Figure 8.18 A typical door panel retaining clip
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Figure 8.19 Plastic or metal trim tools are available to
help the technician remove interior door panels and
other trim without causing harm
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Figure 8.20 Pins come in various types
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Figure 8.21 Various types of rivets
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Figure 8.22 All of the nuts shown are used by themselves
except for the pal nut, which is used to lock another nut to a
threaded fastener so they will not be loosened by vibration
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Figure 8.23 A castellated nut is locked in place
with a cotter pin
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BROKEN FASTENER REMOVAL
• Try not to force fastener and damage head.
• Try tightening in slightly to break corrosion.
• Strike with a punch and a dead blow hammer to
break corrosion.
• Threads may be left-handed.
• Use penetrating oil.
• Properly tighten the fastener.
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THREAD REPAIR INSERTS
• Used to replace original threaded hole.
• Original hole must be enlarged and tapped.
• Insert restores holes to the original size.
• Many types of inserts:
– Threaded inserts
– Self-tapping inserts
– Solid bushing inserts
– Key-locking inserts
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Figure 8.24 Helical inserts look like small, coiled springs. The
outside is a thread to hold the coil in the hole, and the inside
is threaded to fit the desired fastener
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Figure 8.25 The insert provides new, stock-size threads
inside an oversize hole so that the original fastener can
be used
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Figure 8.26 Heli-Coil® kits, available in a wide variety of
sizes, contain everything needed to repair a damaged
hole back to its original size
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Figure 8.27 This solid-bushing insert is threaded on the
outside, to grip the workpiece. The inner threads match
the desired bolt size
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Figure 8.28 A Timesert® kit includes the drill (a), the
recess cutter (b), a special tap (c), the installer (d), and
the Timesert® threaded bushing (e)
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Figure 8.29 Drill out the damaged threads with
the correct bit
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Figure 8.30 Use a special tap for the insert
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Figure 8.31 Put some thread-locking compound
on the insert
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Figure 8.32 Use the driver to drive the keys
down flush with the surface of the workpiece
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Figure 8.33 The insert and insert locks should
be below the surface of the workpiece
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Animation: Installing a Thread Insert
(The animation will automatically start in a few seconds)
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QUESTION 3: ?
How are threaded inserts installed?
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ANSWER 3:
Use the mandrel to screw the insert
into the tapped hole.
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Video Links (Internet Access Required)
• Removing Broken Fasteners (time 29:18)
• Removing Plastic Auto Body Fasteners (2:03)
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Copyright
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