Had another thread about chasing fuel pressure… and solved it with a mechanical pump from RobbMc, but I discovered something less-than-ideal™ when I removed the old Stage-1 pump: a stripped fuel pump bolt hole. I found evidence of a broken thread insert when I backed out the bolt. *Of course* it’s the right one that is open to the inside of the front cover. I must have installed the insert when I built the engine in the mid-1990’s. I only have one bolt tight. I had to get it running and out of the garage as I picked up a mid-rise lift on Craigslist, and it needed to go in the spot where the car was… So, anyone have any success with packing the opening from behind with a lint free cloth full of grease, and installing a threaded insert? I'm looking for alternatives before the inevitable.
You have access to the back side of the threaded hole when the fuel pump is removed--by reaching in through the pump lever hole. "I" would cram in another threaded insert of the same style that was already in there--I'm picturing a Heli-Coil, or Perma-Coil style insert, but perhaps it's something else. The cover would already be tapped--no re-tapping and no metal chips. Remove the remains of the existing thread insert, spin a new one in. The only things you'd need to "catch" from the back side of the hole would be whatever remains of the existing thread insert, and the installation tang of the new insert. Seems very do-able if the remains of the old insert can be removed without screwing-up the casting. If the oversize tapped threads that accept the insert are damaged...things could get "interesting".
I hate when threads go unanswered... and it's been a while since I've made it back here (or to even touch the car, unfortunately). I wound up cleaning out the right hole as best I could, using a grease covered lint-free towel covering the hole from behind. I then threaded a stud into what's left of the hole, with a touch of JB Weld. The left side wasn't great either, but for that one I used a smaller bolt (with bigger washers) and ran it through the new pump and the outside of the housing. So far, so good - drove it a bit and no leaks. Next up is an oil change. (I'll be keeping the TA front cover in the online shopping cart)
