Club 80-90 Forums

I recently checked under my 1.6D camper and found that I had lost one of the bolts that hold the exhaust mount bracket/plate onto the sump. One of the other bolts will not torque up either, I have found a replacement bolt for th missing one and it will not tighten up, it goes in OK but just stops tightening and just turns. Does anybody know how I could fix this? I am guessing that the threads in the sump have been stripped in the past by over tightening.

I thought I could just re-tap the current holes with a larger tap and fit larger bolts, if this is possible some advice as to which sizes would work would be appreciated.
Alternatively I thought maybe a helicoil but I have never used these so more advice again please if this would be preferable.

I would like to replace the bolts with studs that I could wind into the newly tapped sump with thread lock on so that is future I could use nuts to secure the exhaust mount plate to the new studs.

My main concern is that the sump is soft alloy and I do not know what sort of thickness the original bolts have been drilled into. I would not want to drill the sump only to find that I have punctured and ruined it by drilling too large or deep a hole.

Any advice or offers of a replacement sump that doesn't cost an arm and a leg would be greatly appreciated

I would fit Helicoil and studs!
Good luck.

Many years ago I had the same. My quick fix has become permanent!

Very good Oldie,[I must learn how to weld,my daughter can!!]

Thanks for the replies, I do not have a welder, although I would love to get one and learn to weld, so I think a helicoil will have to do. I think a helicoil will give extra strength to the alloy sump so that future removals of the bolts will be turning in a stainless steel thread rather than the soft alloy metal that the sump is made of.

I just need to work out which size helicoil I need now.