So the outside hole on the 240D's intake manifold(?) where the air cleaner housing mounts is stripped out. The thing bounces and rattles like crazy and I'm sure will eventually wear out the inner two mount points. We tried filling the hole with metal JB weld and threading the bolt back into it. Lasted fine until yesterday when we went canoeing and had to go down about 5 miles of rough dirt road. We have it wired down tight now, but I hate sloppy fixes like that on this car.

Is that manifold aluminum? What to do for a permanent fix? I'd hate to replace the whole thing.NO P and P's around here at all.

__________________
You're a daisy if you do.
__________________________________
84 Euro 240D 4spd. 220.5k sold
04 Honda Element AWD
1985 F150 XLT 4x4, 351W with 270k miles, hay hauler
1997 Suzuki Sidekick 4x4
1993 Toyota 4wd Pickup 226K and counting

I should add, we used the JB dough stuff, not the liquid. Maybe the dough's not strong enough.

__________________
You're a daisy if you do.
__________________________________
84 Euro 240D 4spd. 220.5k sold
04 Honda Element AWD
1985 F150 XLT 4x4, 351W with 270k miles, hay hauler
1997 Suzuki Sidekick 4x4
1993 Toyota 4wd Pickup 226K and counting

Kits aren't exactly cheap, but much faster and easier than replacing the manifold. A Helicoil is a thread-repair insert. Drill the hole out a little bigger, use the appropriate tap (included in the kit), thread in the helicoil, fixed. M5x0.8?? I'd replace the shock mount, also, as the threads on that one are undoubtedly buggered.

Jay.

__________________
On the road, currently:
'83 300D (German spec.) 168k mi. - - Wolfgang (tucked snugly away for the winter!)
'87 300D 375k mi. - finally went over to "The Dark Side"
'87 300TD 225k mi.
Cannondale 66cm CAAD5 w/Campy/Jamis Aurora
Hujsak Custom Fixie/Landshark Track Shark Custom/Ahearne Custom 29'er

Has any one tried to source a shock/mount with a longer threaded stud? You could then just drill through & put a nut on the other side. I dont think they are long enough in standard form to do it.

__________________
Grumpy Old Diesel Owners Club group

I no longer question authority, I annoy authority. More effect, less effort....

1967 230-6 auto parts car. rust bucket.
1980 300D now parts car 800k miles
1984 300D 500k miles
1987 250td 160k miles English import
2001 jeep turbo diesel 130k miles
1998 jeep tdi ~ followed me home. Needs a turbo.
1968 Ford F750 truck. 6-354 diesel conversion.
Other toys ~J.D.,Cat & GM ~ mainly earth moving

Thanks! I have spare shock mounts, would I be able to take one in to NAPA or wherever and determine which kit I need? I've never done it before but it doesn't look real complicated.

__________________
You're a daisy if you do.
__________________________________
84 Euro 240D 4spd. 220.5k sold
04 Honda Element AWD
1985 F150 XLT 4x4, 351W with 270k miles, hay hauler
1997 Suzuki Sidekick 4x4
1993 Toyota 4wd Pickup 226K and counting

I thought of that too. They're not long enough.

__________________
You're a daisy if you do.
__________________________________
84 Euro 240D 4spd. 220.5k sold
04 Honda Element AWD
1985 F150 XLT 4x4, 351W with 270k miles, hay hauler
1997 Suzuki Sidekick 4x4
1993 Toyota 4wd Pickup 226K and counting

Those little mounts are common enough. They are used in all sorts of applications, our washing machine even has similar ones! I have never needed to worry but if I did, i would be looking at catalogs to see if I could get a suitable one.

__________________
Grumpy Old Diesel Owners Club group

I no longer question authority, I annoy authority. More effect, less effort....

1967 230-6 auto parts car. rust bucket.
1980 300D now parts car 800k miles
1984 300D 500k miles
1987 250td 160k miles English import
2001 jeep turbo diesel 130k miles
1998 jeep tdi ~ followed me home. Needs a turbo.
1968 Ford F750 truck. 6-354 diesel conversion.
Other toys ~J.D.,Cat & GM ~ mainly earth moving

Will be expensive, but they should be able to help. Just take a good shock mount with you and they can determine the stud diameter (5mm) and thread pitch (0.8).

Cheers!

__________________
On the road, currently:
'83 300D (German spec.) 168k mi. - - Wolfgang (tucked snugly away for the winter!)
'87 300D 375k mi. - finally went over to "The Dark Side"
'87 300TD 225k mi.
Cannondale 66cm CAAD5 w/Campy/Jamis Aurora
Hujsak Custom Fixie/Landshark Track Shark Custom/Ahearne Custom 29'er

There is the poor man's helicoil.

Drill and tap the manifold for the largest, course thread stud (or bolt) that will fit. Then drill/tap the stud to match the mount. Locktite the stud in place.