I'm in a real jam! I intended to replace the starter motor on my 2003 MDX due to the starter noise at cold start. The starter is attached to the engine block with two M10 x 1.25 hex bolts. I had a hard time to take off the hex bolt at the top, but removed the old starter anyway. When I try to put the new starter on, the top one is not going in! So I tried spraying WD40 on the bolt and forcing it in, but not going well. I didn't want to drive the hex bolt too hard to break it in the bolt hole or mess up the engine! So the top portion of the bolt hole thread is stripped - see the picture. I have searched options: helicoil, tap/die, thread chaser... I don't think tap/die or helicoil is an option considering the tight space without taking the engine out (Errr! Just thinking bout it!).

I can't find a 10mm x 1.25mm thread chaser anywhere online or in tool stores in the DC area.

What are my options? If I bring the car to an ACURA dealer, what will they possibly do to fix it?

 

Call an AutoZone or Napa Store in your area and ask them to see if they have that for you..They Should..

 

They don't. I tried Fastenal and Grainger, they have to special order an Nicholson thread restoring file. But no one knows if that will work.