GAH! Bolt won't go back in.

Why not buy a new bolt from Ford? Even if you pay for overnight, it will still probably be $50 or less.

logdog said:

psealso not your fault cbonneheads iburn it in to keeo nthe line dr ollingthis inchvalve said:

Well, life is sucking more tonight.  I double-checked the bolt and it is a M14 - 2.0.  They do not make a thread chaser in that size. I can get a tap, but not sure if that is the best option. This is really pissing me off, this project should be done.  

I am tempted to go the impact wrench route, but I think it will simply strip the capture nut from the frame then I will really be up Shlitz Creek. 

You can make your own thread chaser from another bolt.  I picked up that tip from an offroad magazine years ago and have done it a few times.  Something like This

In reply to TRoglodyte :

I just broke the internet, can i get an attaboy?

The bolts were fine, it was the threaded hole. My guess is that the subframe was dropped to do the LSD and the bolt went back in with an impact wrench slightly crooked. Can’t say for sure. 

Doesn’t look too bad in there.  I ran a tap through because it was all I could get in that size. It cleaned out the first few threads then went pretty easy the rest of the way. 

The bolt went back in, but was tough to turn the whole way. Didn’t need an impact wrench, but it was REAL tight. Hoping to never remove it again. 

Glad you got it resolved..  The bolt probably stretched when it was impacted into place.  Now that you ran a tap through the nut, it's properly spaced which means your stretched bolt was forced against it the whole way up. 

I'm looking at that and reading the article, and I want to make sure I understand it right. 

They are saying have a 90 degree angle on the forward engagement side of the threads and to put a tapered angle with a little garbage collection area behind it on the trailing end of the threads, right?

In reply to Brett_Murphy :

That's overkill thinking.  I would just cut a notch with the corner of a bench grinder, or the edge of an angle grinder  and that's plenty good.

I maoe chasers like this all the time.  They are only good for a few thread restorations so there is no sense in making them perfect.

Just make sure the notch is deeper than the thread root so any gick has a place to actually go.