At Tue, 14 May 1996 16:40:25 -0500 (CDT), Jon Christensen
<vvwca@primenet.com> wrote:
>
>On Tue, 14 May 1996, Mike White wrote:
>> Seems all the bolts but ONE fell out of the driver side reduction
>> box/swingarm assembly.  I got under there last night to install a
>> couple new bolts, and noticed one bolt was sheared off.  ACK.
>(snip)
>
>I had similiar experiences.  My solution was to disassemble it down to
>the swing tube, take it to a machine shop and have them put thread
>inserts into the soft metal inner casing of the reduction boxes.  It is a
>good idea not to use any 'screwed' up bolts when you put it all back
>together.  8-)    Good luck.

The Bozobus went the Heli-Coil path as well.
Did the "machining" myself.
The Heli-Coil kit was *expensive*, and I had to go to a FLAPS warehouse
supply outlet to get it (something like $54US in '91).
Try to get the "self-locking" variety of insert - this reduces the reliance
on the bent tab-thingy or simple split-ring lockwashers to keep the bolts
in place.

Be careful not to punch through *into* the oil-filled xfer case.
The gear oil is smelly and expensive, and it's disheartening to watch it
flow straight through to the floor.
I did this twice (years apart). Fixed the leak by putting a huge gobbet of
PermaTex #2 (or #3?) in the hole bottom and on the end of the bolt.

bcnu - Grungy           (Houston, TX)
jgladu@bcm.tmc.edu
'60 dddPanel walk-thru  (The Bozobus)
'89 Vanagon GL
'90 Vanagon GL
'68 & '69 Bugs          (Frunobulax & Bertha)