I was under the truck today working on something else and noticed a horrendous amount of trans fluid sprayed all over the place. Looked at the mag double deep pan I put on a year ago and noted that FOUR (4) of the mounting bolts were GONE. The Mag pans never seal properly, probobly due to the low torque spec that protects the cast aluminum, but I didnt expect them to fall out! All of the bolts were torqued to the spec that came with the directions, but ALL of them were loose and four fell out completely.

Now the really bad part; I went down to the hardware store to buy some replacement cap screws. I took an existing bolt (from Mag Hytech) with me and it appeared to fit and thread fine into the metric bolt guage at the store in the M8 1.25 pitch threaded hole. So, thats what I bought. After threading the first one in, it went fine for about 3-4 turns then got harder and harder, I thought maybe that hole had some debris in it, or was stripped before so I tried the next hole- same deal. Now the original bolts won't even start to thread in the two holes I tried the new bolts in. Anyway, those two holes are now stripped and I was wondering if anyone has any ideas on how to fix the them, and if theres any type of lock washer that would work in this situation? I thought about using LocTite, but that could present problems.

 

Go to a auto parts store and get you a helicoil, it will be stronger than before.
http://www.helicoil.in/index.htm

 

I've heard of heli-coils before, but I've never installed one, do you need special tools?

 

Have you heard of others having this problem? Your MH must be an isolated case. I have been on DTR almost every day for 4 years and have never read a single problem regarding the MH DD pan.

Mine has been on my truck since 15K miles.....and it's currently at 104K with no trans leaks.

Have you contacted Mag-Hytec or your vendor? They may be able to replace your pan bolts, gasket, etc....and get the problem corrected.

..

 

I have a MH diff cover and never had any problems...it's about 4 yrs old.

 

The bolts that hold the pan to the tranny are not metric. I think they are 5/16-18.

 

It should come with everything you need in the pack. I dont know if a cheap kit comes with a tap and bit but you can get them anywere.

 

I had one bolt fall out after initial install.... with two others being very loose (no spraying or leaking).
Since then I have paid attention to accurate and even tq and had no problems (727DD been on for 140,000 miles).

RJ

 

You will need a different drill and tap for a helicoil, tell them your size
and they will give you correct size. Take a piece of round metal
and cut a slot in the end, use this to turn helicoil in.

 

The best fix is a TIMESERT kit. Thin wall solid steel insert.Kit comes with all the tools(drill,tap,countersink,insert tool,numerous inserts)They install perfectly every time.They will not unwind or damage bolts like helicoils sometimes will.Google timesert.They are in Nevada I think.Super helpfull staff.
Good luck, And I will be checking my pan now.

 

I do not understand this sentence, what kind of problems?

 

Instead of taking the time and effort to install heli-coils, you might want to try using a tap and dye set and running the correct tap into the stripped holes.

If you only went in 3-4 turns with the metric bolts, there may still be enough useable threads in the existing holes and you might be able to save them.

I bought a cheap Tap & Dye set from Harbor Freight for around $25 when I installed my thermocouple, and while it's not the best quality (made in China), for the few times I've needed it it's worked great.

 

Mine loosened up constantly on the '99. Fred Swanson did the DTT upgrade and recommended Loctite on the nuts. I was faithful about using Loctite except one time when they loosened up again.

 

I would think that lock washers would prevent this

 

Knocking on wood here, but I put mine on at 36k miles and im at 58k now and no leaking/loose bolts....