Chapter 9 Fastener Gasket and Sealant

by
Russell Krick
Publisher
The Goodheart-Willcox Co., Inc.
Tinley Park, Illinois
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only
(9 Topics)
 Fasteners
 Washers
 Machine screws
 Sheet metal screws
 Nonthreaded fasteners
 Torquing bolts and nuts
 Thread repairs
 Removing damaged fasteners
 Gaskets and seals
 Devices that hold the parts of a vehicle
together
 Thousands of fasteners are used in
vehicles
Automotive Fasteners
Bolts and Nuts
 Bolt
 metal rod with external threads on one
end and a head on the other
 when a bolt is threaded into a part other
than a nut, it can also be called a cap
screw
 Nut
 has internal threads and, usually, a six-
sided outer shape
Bolts and Nuts
When a nut is screwed onto a bolt, a

powerful clamping force is produced
Bolt Dimensions
Bolt Dimensions
Thread Types
 There are three basic types of threads
used on fasteners:
 Coarse threads
 UNC-Unified National Coarse
 Fine threads
 UNF-Unified National Fine
 Metric threads
 SI
Thread Direction
 Bolts and nuts come in right- and left-
hand threads
 Right-hand threads
 fastener must be turned clockwise to
tighten
 Left-hand threads
 fastener must be turned counterclockwise
to tighten
 letter L may be stamped on fastener
Bolt Grade
 Also called tensile strength
 Refers to the amount of pull a fastener
can withstand before breaking
 Bolt head markings specify the tensile
strength of the bolt
 U.S. customary bolts are marked with
lines
 Metric bolts are marked with numbers
Bolt Description
Gives information about the bolt

Bolt Description
Used when purchasing new bolts

Bolt Description
Nut Types
Common types of nuts used in vehicles
Castle Nut and
Cotter Pin
Cotter pin keeps the nut from turning and

possibly coming off
 Used under bolt heads and nuts
 Two basic types of washers are used:
 flat washers
 lock washers
Washer Types
 Flat washer
 increases the clamping surface under the
fastener
 prevents the bolt or nut from digging into
the part
 Lock washer
 prevents the bolt or nut from becoming
loose under stress and vibration
Washer Types
 Lock tabs or lock plates
 perform the functions of both flat washers
and lock washers
 increase clamping surface area and
secure the fastener
Washer Types
A. Plain flat washer B. Split lock washer

C. Toothed lock washer D. Lock plate
 Similar to bolts, but they normally have
screw-type heads
 Threaded along their full length
 Used to secure parts when clamping
loads are light
 Available in various head shapes
 Also called tapping screws
 Commonly used on plastic and sheet
metal parts, such as body trim,
dashboard panels, and grills
 Use tapering threads that are widely
spaced
Sheet Metal Screws
Numerous types of nonthreaded
fasteners, such as snap rings, clips, and
adhesives, are used in the assembly
of a vehicle
Snap Ring
 Fits into a groove in a part and
commonly holds shafts, bearings,
gears, pins, and other components in
place
 Snap ring pliers are needed to remove
and install a snap ring
special jaws grasp the snap ring
Snap Ring Types
Keys and Set Screws
 Key
 prevents a part from turning on its shaft
 fits into a keyseat (slot) cut into a shaft
and a keyway cut into the mating part
 Set screw
 normally used to lock a part onto a shaft
 not as strong as a key
Keys and Set Screws
A. Key
B. Set screw
Splines
 Series of slots cut into a shaft and a
mating part
 Allow the gear or collar to slide on the
shaft but still not rotate
 Used in manual transmissions,
clutches, and drive shaft yokes
Splines
Adhesives
 Special glues widely used in vehicles
 Used to hold body moldings, rubber
weather stripping, and body emblems
 Some stay soft and pliable; others dry
hard
 Some take hours to dry; others dry in
seconds
 Observe all directions and safety
precautions when using adhesives
It is very important that bolts and
nuts be tightened properly—this is
called torquing
Torque Specifications
 Tightening values given by the auto
manufacturer
 Normally given for all precision
assemblies, such as engines,
transmissions, and differentials
 Factory specifications should be used
 general bolt torque chart may be used if
factory specs are not available
Bolt
Torque
Chart
Torque-to-Yield
 Requires a bolt to be tightened to a
specific torque and then turned an
additional number of degrees
 Procedure stretches the bolt to its
correct yield point, preloading the
fastener for better clamping under
varying conditions
 New bolts may be required each time
Torque Stretch
 Determined by measuring bolt length
change while torquing the bolt
 when building a racing engine, you can
“mike” connecting rod bolts to measure
the length before and after tightening
 Too much stretch indicates bolt
weakness
 Not enough stretch may indicate thread
problems affecting torque
Bolt Tightening
Sequence
 Used to make sure that parts are
fastened evenly
 Creates an even, gradual clamping
force along the entire mating surface of
the parts
 Crisscross pattern is often
recommended
Bolt Tightening
Sequence
10 6 2 3 7
9 5 1 4 8
Service manual pattern for a cylinder head
Bolt Tightening
Sequence
Service manual pattern for wheel lug nuts

Torque Wrench Rules
 Keep a steady pull on the wrench
 Clean fastener threads
 Avoid using swivel joints
 When reading a torque wrench, look
straight down at the scale
 Use manufacturer’s specifications
when available
Torque Wrench Rules
 When manufacturer’s specs are not
available, use general specs in a
crisscross pattern
 To avoid a false reading, pull only on
the handle
 Tighten bolts and nuts in four steps
 Retorque when required
 some assemblies must be retightened
after operation and heating
Threaded holes in parts can become
damaged, requiring repairs. A technician
must be capable of repairing damaged
threads quickly and properly.
Minor Thread Repairs
 Minor thread damage includes nicks,
partial flattening, and other less serious
problems
 Minor damage can be repaired with a
thread chaser or a thread file
 the thread chaser is run through or over
the threads to restore them
Major Thread Repairs
 Badly smashed or stripped threads
may be repaired with either a tap or die
 Tap
 threaded tool for cutting internal threads
in holes
 Die
 cuts external threads on metal rods, bolts,
shafts, and pins
Tap and Die
Using a Tap and Die
 Hold the handle squarely with the work
 Back the handle off to clean metal out
of the threads
 Use a taper tap to start the threads
 Use a plug tap and a bottoming tap to
cut the threads to the bottom of the
hole
Tap and Die Rules
 Never force a tap handle or the tool
may break
 Keep the tap and die well oiled to ease
cutting
 Use coarse threads when threading or
tapping into soft metal, like aluminum
 coarse threads will hold better than fine
threads
Tapping Oversize
 When threads cannot be restored, the
hole can be drilled and tapped oversize
 Use a “drill and tap size chart” to
choose a drill bit and tap
 Drill the hole one size larger than the
original hole
 Cut new threads in the drilled hole
 Use a larger bolt in the threaded hole
Thread Repair Insert
 Used when the use of an oversize hole
and fastener is not acceptable
 Takes place of damaged internal
threads
 Allows the use of the original-size bolt
Using an Insert
A. Drill the hole
oversize
B. Tap the hole
oversize
C. Mount the
insert on a
mandrel
D. Thread the
insert into the
hole
Using an Insert
Insert allows the use of the original-size bolt
Using an Insert
Damaged threads Installed insert

before a repair
 An automotive technician must be able
to remove broken bolts, screws, and
studs, as well as fasteners having
rusted or rounded-off heads
 Specific tools and methods are needed
for removing problem fasteners
Removal Methods
 Grasp a rusted or rounded head with
locking pliers
 Use a stud puller or stud wrench
 removes studs and bolts broken off
above the surface of the part
Removal Methods
 Cut a slot in the fastener with a
hacksaw or weld on a nut to grasp
 Use a hammer and punch
 angle the punch so that blows from the
hammer can drive out the broken
fastener
 Drill a hole almost as large as the
inside diameter of the threads
 use a tap or punch to remove the thread
shell
Removal Methods
Using a screw extractor
A. Drill a hole
B. Tap the extractor into the hole
C. Unscrew the extractor and bolt
Removal Methods
Use rust penetrant to help ease turning

and prevent fastener breakage
Used between parts to prevent leakage of
engine oil, coolant, transmission fluid, and
other fluids
Gaskets
 Soft, flexible material placed between
parts to prevent leakage
 Made of fiber materials, rubber,
neoprene (synthetic rubber), cork,
treated paper, or thin steel
 When parts are fastened together, the
gasket material fills small gaps, dents,
or scratches in the mating surfaces
Gasket Rules
 Inspect for leaks before disassembly
 Be careful not to damage mating
surfaces while removing parts
 Clean off old gaskets carefully
 Wash and dry parts thoroughly
 Compare the new gasket to the shape
of the mating surface
Gasket Rules
 Use a sealer if specified
 When assembling, start all bolts by
hand
 Tighten fasteners in steps
 Use a crisscross tightening pattern
 Do not overtighten fasteners
 apply only the specified torque
Sealers
Gaskets are often coated with a sealer to

help prevent leakage and to hold the
gasket in place during assembly
Types of Sealers
Form-in-Place Gaskets
 Used instead of conventional fiber or
rubber gaskets
 Two common types are:
 room temperature vulcanizing (RTV)
sealer
 anaerobic sealer
RTV Sealer
 Also called silicone sealer
 Dries in contact with air
 Used to form a rubber-like gasket on
thin, flexible flanges
 Available in tubes
has a shelf life of one to two years
RTV Sealer
Commonly recommended where two

different gaskets join
Using RTV Sealer
 Apply in a continuous bead that is
approximately 1/8” (3 mm) wide
 Circle all mounting holes
 Torque components in place while the
RTV is still wet to the touch
 within about 10 minutes of application
Anaerobic Sealer
 Cures to a plastic-like substance in the
absence of air
 Designed for tightly fitting, thick parts
 Used between two smooth, true
surfaces
Using Anaerobic
Sealer
 Apply in a continuous bead that is
approximately 1/16"–3/32" (1.5 mm–
2 mm) wide
 Circle all mounting holes
 Torque components in place within 15
minutes of sealer application
Using Sealers
Both anaerobic and

RTV sealers are
used on this water
pump
Seals
 Prevent leakage between a stationary
part and a moving part
 Found in engines, transmissions,
power steering units, and any part
containing fluid and moving parts
 Made of synthetic rubber molded onto
a metal body
Seal Application
Seal lip faces the fluid and keeps it

inside the part
Seal Rules
 Inspect the seal for leakage before
disassembly
 if the seal is leaking, look for a bent shaft,
misaligned seal housing, or damaged
parts
 Remove the old seal carefully, without
scratching the seal housing
Seal Rules
Inspect shafts for wear and burrs
Seal Rules
 Compare the old seal to the new seal
 make sure the inner and outer diameters
match before installation
 Install the new seal correctly
 coat the outside with an approved sealer
 coat the inner lip of the seal with system
fluid
 install the seal with the sealing lip toward
the inside of the part
O-Ring Seal
 Stationary seal that fits into a groove
between two parts
 When the parts are assembled, the
synthetic rubber seal is partially
compressed to form a leakproof joint
O-Ring Seal
Normally, the O-ring seal is coated with

system fluid before installation
Synthetic Seal
Specially-shaped seal that fits down into a

groove formed in the part

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by

When a nut is screwed onto a bolt, a

Gives information about the bolt

Used when purchasing new bolts

Common types of nuts used in vehicles

Cotter pin keeps the nut from turning and

A. Plain flat washer B. Split lock washer

Service manual pattern for a cylinder head

Service manual pattern for wheel lug nuts

Insert allows the use of the original-size bolt

Damaged threads Installed insert

Use rust penetrant to help ease turning

Gaskets are often coated with a sealer to

Commonly recommended where two

Both anaerobic and

Seal lip faces the fluid and keeps it

Inspect shafts for wear and burrs

Normally, the O-ring seal is coated with

Specially-shaped seal that fits down into a

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