I was disassembling the TPI I just purchased for a conversion and found the head of one of the TPS screws has been snapped off . I tried to gently get it out but it snapped off flush with the housing . What is the best, safest way to get the rest of the screw out? I had considered drilling it out and putting in a helicoil but got worried that I may crack the TB housing. Has anyone done the helicoil fix and if so what size did you use? My only other option is to find a replacement.

 

Don't sweat it man, get a reverse drill bit and run that puppy out or get a drill bit the exact same diameter as the screw, center punch the screw and drill it out, then run a tap down trugh it to clean it back up. Its not a critical screw so if a few threads get damaged it wont matter!

 

You happen to know what size tap I'll need? I tried to drill it out after I posted this but didn't get too far. I then tried an easy out and actually drove the screw down into the hole. I didn't see anywhere it could come through at so I'm assuming it's a blind hole. The depth of the damaged hole matches that of the good one so I'm thinking maybe I could get away with retapping it or worse case having to drill out and retap both holes. Thoughts?

 

Do what I did for same problem, take the throttle body to a machine shop & let them do it. It's not to expensive & they have all the right tools & you don't have to worry about scewing it up!!!!

 

I did the same. Made due with just one screw for a few months until I got a new engine (not because of the screw). I'd say take it to someone that knows what they are doing if you can- it's easy enough. Drilling and just drilling another screw into the hole would be very easy- the TB is soft and its not a critical screw if anything did happen.

 

Thanks for the replies. I was able to fix it myself. Went down to the local Fastenal store and got a helicoil kit and a bag of SS allen head bolts. Then just drilled the holes out a bit, retapped them to standard fine threads, inserted the helicoils and viola! All is well now.

 

Heh heh....

I think almost every DIY'er TPI-nut has broken off those el-cheap-o pot metal TPS screws.