Lug bolt thread repair - MINI

Looking for thought on this before a start the repair. 

Last night while having winter tires installed, the shop kindly informed me that on off the wheel bolts (lug bolts, whatever the proper term is) was found to be cross threaded when removed. 

Seems a bit suspicious to me, since they didn't tell me about it until handing over the keys before I realized they hadn't given me the lug key and noticing they hadinstalled the wrong size tire (you can see more details about the experience in the minor rant thread).

So now I need to fix it, and my plan was to start with a thread chaser, if that doesn't work then move on to a helicoil, and a new hub as the last resort. 

Anyone see any flaws with that approach? The helicoil should be as strong as the original thread, but I'm open to opinions. 

It's so hard to cross thread those wheel bolts, you really have to try.....

I think a thread chaser should clean it up if the threads aren't completely borked. if they are, I would consider finding a hub in a scrap yard rather than a helicoil....even tho I'm a fan of helicoils.

I'll pull the wheel tomorrow and get a better look. I hate to have to replace the hub, but I guess with only 4 lug bolts it probably safer. 

I've tapped stripped M12x1.5 hub threads out to M14x1.5 using a 1/2-20 tap as an intermediate step.

I'd use a thread chaser as mentioned (NOT a tap; taps cut threads, thread chasers reshape the existing ones) and if you can still torque it to spec, it's fine.

Given that hubs are generally a disposable, if it comes to helicoiling. I'd just replace the hub.  Helicoils can come out with the fastener sometimes, especially in non blind threaded holes where the end of the bolt is exposed and can get rusty. 

Let's hear it, please include your rant.

VolvoHeretic said:

Let's hear it, please include your rant.

From the minor rants thread:

Spent 2+ hours last night to have the local chain tire shop install the wrong tires, tell me that a lug bolt was cross threaded when they took it out, and they couldn't complete the alignment because the adjuster is frozen,  didn't put the spline drive for the lug bolts back in the car, and the TPMS light was on leaving. Of course it was closing time so they could do anything last night, and I'm back again today.

Shame on me for believing them when they said them when they said the lug bolt was the issue and the hub threads are good. I ground off the bad threads, and cleaned up the end taper and "surprise" it won't thread in, and they are insistent that they didn't mess it up.

I've been here an hour waiting for them to get the right tires on, and will need to come back after I free up what I believe it going to be the tie rod end. Although at 23k miles and no winters I find it hard to believe it's frozen. 

I pulled the wheel off today to see what the damage looked like and stopped at that point to call the tire shop. 

It's going to the garage near them to be "evaluated " to see if the damage is something they might have caused. If they agree it was during the install

the next challenge will be getting them to use oem parts(or at least skf or tinker). At 24k miles that factory bearing had a lot of life left in it. 

Based on the photos I think someone cross threaded the wheel bolt and they tried to pass it off as preexisting damage. 
 

Just to make matters worse, I was going to pull the left front wheel off and get the tie rod freed up, but one of the lug bolts felt funny. These were fine and threaded in by hand when reinstalling the wheels after I replaced the clutch. 

It definitely didn't feel right, but I figured I'd work it back and forth to see if it was dirt or really a problem. After less than 2 turns it was getting tighter to where a 1/2" ratchet didn't want to turn easily. 

I just tightened the front wheel back up and was able to torque all 4 bolts to the 103 ft-lb spec.  I'll have the shop that's doing the inspection on the right rear check them all and give me an estimated for getting the tie rod freed up so the alignment can be finished  

So it went in for inspection today and I asked them to check all 4 wheels since I had noticed something was up with at least 1 of the front wheel bolts. 

The verdict is 2 rear hubs, and at least 1 wheel bolts per corner. The front hubs could be cleaned up with a thread chaser, but the bolts should be replaced.

I'll call the tire shop this afternoon and make it clear I want oem parts used. That may be the way the shop making the repair goes anyway, but I want to be sure. 

Yeah, we all know what happened, the "tech" aka "tire monkey" stuck the bolt in the hole and hit it with the impact wrench......

I'd be mad as hell too.

And it's why I would NEVER take my car to one of the oil change shops......their business model does not allow for time to train people properly, they have so much turnover that they're desperate for anyone that can fog a mirror, and this is what you get.