I've noticed a LOT of threads get stripped when working on my twenty-year-old D17a2 Civic engine. I'm open to the idea that I'm doing something wrong, but I try to feel with my hands what the bolts are doing, try to keep motion smooth, etc. My engine class instructor mentioned aluminum gets tired with age and becomes more prone to failure. Hopefully he was correct and not just trying to make me feel better. I just expect to pull threads on every repair now, and keep an expanded Time-Sert master kit on hand. Which wasn't cheap, but is worth it. Do you guys find your soft aluminum engines are constantly breaking off threads when removing bolts?

 

Do you use hand tools or power tools for dis-assembly ?

 

Both

 

Are you using a torque wrench to reassemble bolts?

 

Keeping smooth motion is what always breaks em off for me. Use a rubber mallet and tap lightly on a wrench till it moves. Or use an impact on low setting for most bolts. If they are under 70ftlbs they should come out easy and if they don't, apply heat. While its hot, use light impacting force to break it free. With my dewalt impact I would just stand on an LCA bolt on level 1 after heating it, and eventually it will back out. Those are only 42ftlbs, usually they get seized in the bushing sleeve. Yeah heat cooks the bushing but usually thats your sign its time to replace.

Torque wrench for all bolts over 25ftlbs. Hand tools gently for less. Chocking up on the wrench helps reduce your ability to over tighten. Wrist twist strength is usually fine for m6s.

Use torque specs, don't guess.

Once the bolt moves, turn back and forth, like you are tapping a hole, to allow debris to clear. Use penetrating oil. Be patient.

Heat, oil, light impact, patience, torque wrench.

 

theYBLEGAL these are all good suggestions. Mostly I have used smooth, even motion with socket wrenches, thinking that erratic or impact force is more inclined to break threads. But as you say the opposite may be true. I am usually very careful and use torque wrenches whenever possible. Good tip on "like tapping a hole" too.