Help with rocker box covers.

mymastiff

mymastiff

Active Member
So, I go to finish installing new gaskets on the rocker box covers, all done and I start to bolt them up and only a couple of the bolts on the front cover will tighten up, I guess they are stripped.:bang::bang: Barely any pressure applied and once I started with the torque wrench they only spin. Has anyone else encountered this? Guessing this means new boxes? Any suggestions would be greatly appreciated. The back cover bolts tightened up fine although I was nervous as hell about tightening them up.
 
Little-Boo

Little-Boo

Well-Known Member
Troop Supporter
Man you must have a hell of a heavy hand :lol::lol: Take one of the bolts off go to an auto supply store and get a helicoil kit. You will have to take the box off to get the job done without any metal shaving getting into the motor. I have used helicoil before and it hold up really good.

Good Luck
 
BBChopper

BBChopper

Supports 2 Disabled Vets
Troop Supporter
Little-Boo said:
Man you must have a hell of a heavy hand :lol::lol: Take one of the bolts off go to an auto supply store and get a helicoil kit. You will have to take the box off to get the job done without any metal shaving getting into the motor. I have used helicoil before and it hold up really good.

Good Luck
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Yup that sucks check the bolts make sure they are correct!!!!:(
 
V

V

Guru
When you pull the bolts out (prob already have) pull straight out. that way you can pull the stipped sprial of aluminum out. Ask me how I know :bang:

Now I did this on one of my front cover corner bolts. I got a new chrome bolt a 1/4" longer than the stock and it caught good enough to hold 80 in lbs for a couple of years now. When I did strip the bolt the first time I did get the aluminum sprial out and pulled the cover to clean up any thing I could find. If I remember (don't have the manual in frony of me) the specs call for 100-120 in lbs torque. I split the torque in the middle 110 in lbs and it stripped. I have them all at 80 in lbs and blue loktite with no leakage.
 
mymastiff

mymastiff

Active Member
I didn't get anywhere near 100 before they spun, there was 2 washers on each so I took it one off on one and both off on another but they still probably didn't hit 80 in lbs, started it up and let it run for about 5 -10 minutes with no leak. Guess the real test would be a speed?
 
RRRUFF

RRRUFF

Well-Known Member
outdoorsman26 said:
can you run a longer bolt in?? I would try before you drill......
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I would try this first. Also are you sure you got the right bolts back in the right holes. I believe some are shorter than others.

If that don't work, helicoil is your best bet. They work well just take your time.
 
mymastiff

mymastiff

Active Member
Yea, I actually got new bolts, the old ones looked shitty, but the new ones were the exact same. Gonna try both options, longer bolt and then helicoil, worst case I just confirmed I can get the base from S&S, not cheap but better than the whole box.
 
mymastiff

mymastiff

Active Member
Buttoned this thing up and rode around the block for awhile, got on it hard many times, no leaks. I'm sure it would eventually, just curious if anyone knows what amount of pressure there is inside the covers? I'm getting the local Big Dog dealer to install the heili coils so I'm confident it will be repaired properly but expected it to leak when I rode it. What gives?
 
V

V

Guru
I'd say buy the extra rocker box for when the problem starts, if it starts and then change it out your self. By the time you have your existing taken off and repaired, labor and gaskets, you could do it your self and prob save some coin, the front is the easy to replace. :2thumbs:
 
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