Doing my timing belt work and replacing the water pump (WP). In 2006 this work was done for the first time since the truck was new.

In 06 I replaced the WP but used the original OEM housing. This time I again just ordered the WP to again reuse the housing. On assembling the WP with new gaskets two of the 6mm bolts stripped out the housing threads.

After examining the threads it turns out the original housing had used Helicoils in all the 6mm thread holes. I'm not sure if this is standard practice for aluminum housings with small bolts that only use about 1/4" of thread purchase or if this was a "fix" by the original OEM supplier. It did hold for over 20 years though.

I have ordered a new complete pump as I did not want to Helicoil again - even if it were possible. In future I might try to Helicoil for 1/4"-20 SS bolts.

So this is just a word of caution for those doing this work.

I've had to heicoil them before, held fine.

Yea, I'm keeping the old housing as I have a new pump for it. I'll try a Helicoil if I ever need a new pump - but given that the last pump lasted 10 years+ I doubt I'll ever see the inside of this engine again.

So today I installed the Gates new water pump with new housing. Tightening the 6mm small bolts that hold the water pump to the housing, one stripped. I had actually separated the housing and water pump to put a little spray-a-gasket on the gasket as I don't trust paper gaskets for very long.

So I had an installed pump on the engine with a stripped out thread. With some testing of the old extra housing I found I could tap a 1/4"-20 thread in the hole left by the Heli-coil, not even having to drill a larger hole. All these housings have Heli-coils.

I used a bottom tap (made from taper tap I had) to thread the hole and then a 1/4"-20 bolt. It tightened properly with good grip. No need to worry about any chips as those can be blown out because the gasket keeps them from getting anywhere harmful.

This saved me from removing the water pump assembly.