Thread Repair Specifications. Chevrolet Tahoe

For 1990-2009 cars

Makes 🢒 Chevrolet 🢒 2004 🢒 Tahoe - 2WD 🢒 Preface 🢒 Cautions and Notices 🢒 Thread Repair Specifications

Table 1:	Engine Block - Front View
Table 2:	Engine Block - Rear View
Table 3:	Engine Block - Left Side View
Table 4:	Engine Block - Right Side View
Table 5:	Engine Block - Bottom View
Table 6:	Engine Block - Top View
Table 7:	Cylinder Head - Top View
Table 8:	Cylinder Head - End View
Table 9:	Cylinder Head - Exhaust Manifold Deck View
Table 10:	Cylinder Head - Intake Manifold Deck View

Engine Block - Front View

Engine Block - Front View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-6	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
7	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	25.0 (0.984)	19.5 (0.767)
8	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	32.5 (1.28)	25.0 (0.984)
9	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
10	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	Thru	Thru
11-13	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
14	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	Thru	18.0 (0.708)
15	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
16	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	Thru	18.0 (0.708)
17-27	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)

Engine Block - Rear View

Engine Block - Rear View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	27.0 (1.06)	21.5 (0.846)
2-4	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
5-6	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	27.0 (1.06)	21.5 (0.846)
7-13	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)
14-16	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	27.0 (1.06)	21.5 (0.846)
17-18	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	22.5 (0.885)	17.5 (0.688)

Engine Block - Left Side View

Engine Block - Left Side View

Hole

Thread Size

Insert

Drill

Counterbore Tool

Tap

Driver

Drill Depth - Maximum mm (in)

Tap Depth - Maximum mm (in)

J 42385

M28 x 1.25

N/A

M8 x 1.25

210

206

207

208

209

28.5 (1.122)

23.0 (0.905)

M8 x 1.25

210

206

207

208

209

21.5 (0.846)

16.0 (0.629)

M10 x 1.25

215

211

212

213

214

29.0 (1.141)

23.0 (0.905)

M10 x 1.5

215

211

212

213

214

27.0 (1.062)

21.5 (0.846)

M16 x 1.5

N/A

M11 x 2.0 First

Design

108

105

N/A

106

107

124.0 (4.88)

115.0 (4.52)

M11 x 2.0 Second

Design

108

105

N/A

106

107

69.0 (2.72)

60.0 (2.36)

M11 x 2.0

108

105

N/A

106

107

69.0 (2.72)

60.0 (2.36)

•	Bolt holes 7, second design, and 8 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2.72 in) drill depth. Use sleeve J 42385-315 with the drill and tap.

•	Bolt holes 7, first design, have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in) drill depth.

Engine Block - Right Side View

Engine Block - Right Side View

Hole

Thread Size

Insert

Drill

Counterbore Tool

Tap

Driver

Drill Depth - Maximum mm (in)

Tap Depth - Maximum mm (in)

J 42385

M28 x 1.25

210

206

207

208

209

22.5 (0.885)

17.5 (0.688)

M8 x 1.25

210

206

207

208

209

26.5 (1.04)

19.0 (0.784)

M11 x 2.0

108

105

N/A

106

107

69.0 (2.72)

60.0 (2.36)

M10 x 1.25

215

211

212

213

214

29.0 (1.141)

23.0 (0.905)

M10 x 1.5

215

211

212

213

214

27.0 (1.062)

21.5 (0.846)

M16 x 1.5

N/A

M11 x 2.0 First

Design

108

105

N/A

106

107

124.0 (4.88)

115.0 (4.52)

M11 x 2.0 Second

Design

108

105

N/A

106

107

69.0 (2.72)

60.0 (2.36)

•	Bolt holes 7, second design, and 3 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2.72 in) drill depth. Use sleeve J 42385-315 with the drill and tap.

•	Bolt holes 7, first design, have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in) drill depth.

Engine Block - Bottom View

Engine Block - Bottom View

Hole

Thread Size

Insert

Drill

Counterbore Tool

Tap

Driver

Drill Depth - Maximum mm (in)

Tap Depth - Maximum mm (in)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

M16 x 1.5

N/A

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

10-11

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

13-14

M10 x 1.5

J 42385-215

J 42385-101

J 42385-213

J 42385-214

42.5 (1.67)

37.0 (1.45)

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M16 x 1.5

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

25-26

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

28-29

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M28 x 1.25

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

M10 x 2.0

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

M8 x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

•	Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm (0.807 in) counterbore included in the 53.5 mm (2.10 in) drill depth.

•	Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm (0.059 in) counterbore included in the 31.0 mm (1.22 in) drill depth. Use sleeve J 42385-316 with the drill and tap.

•	Bolt holes 13 and 14 have a 11.5 mm (0.452 in) counterbore included in the 42.5 mm (1.67 in) drill depth. Use sleeve J 42385-311 with the drill and tap.

Engine Block - Top View

Engine Block - Top View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-4	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)
5	M16 x 1.5	--	--	--	--	--	--	--
6-7	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)
8	M10 x 1.5	J 42385-216	J 42385-211	J 42385-212	J 42385-213	J 42385-214	22.5 (0.885)	17.0 (0.669)
9-10	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)
11	M10 x 1.5	J 42385-216	J 42385-211	J 42385-212	J 42385-213	J 42385-214	22.5 (0.885)	17.0 (0.669)
12-14	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)

Cylinder Head - Top View

Cylinder Head - Top View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-5	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)
6-9	M6 x 1.0	J 42385-205	J 42385-201	J 42385-202	J 42385-203	J 42385-204	20.05 (0.789)	16.05 (0.632)
10-12	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	26.5 (1.04)	19.0 (0.784)

Cylinder Head - End View

Cylinder Head - End View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)
2	--	N/A	--	--	--	--	--	--
3	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)
4	N/A	--	--	--	--	--	--	--
5-6	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)

Cylinder Head - Exhaust Manifold Deck View

Cylinder Head - Exhaust Manifold Deck View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-2	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)
3	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
4	M14 x 1.25	--	--	--	--	--	--	--
5	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
6	M14 x 1.25	--	--	--	--	--	--	--
7-8	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
9	M14 x 1.25	--	--	--	--	--	--	--
10	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
11	M14 x 1.25	--	--	--	--	--	--	--
12	M8 x 1.25	J 42385-210	J 42385-206	J 42385-207	J 42385-208	J 42385-209	21.0 (0.826)	16.0 (0.629)
13	M12 x 1.5	--	--	--	--	--	--	--
14-15	M10 x 1.5	J 42385-215	J 42385-211	J 42385-212	J 42385-213	J 42385-214	28.0 (1.10)	20.0 (0.787)

Cylinder Head - Intake Manifold Deck View

Cylinder Head - Intake Manifold Deck View

Hole	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth - Maximum mm (in)	Tap Depth - Maximum mm (in)
1-2	M6 x 1.0	J 42385-205	J 42385-201	J 42385-202	J 42385-203	J 42385-204	Thru	Thru
3-4	M6 x 1.0	J 42385-205	J 42385-201	J 42385-202	J 42385-203	J 42385-204	22.5 (0.885)	15.0 (0.688)
5-7	M6 x 1.0	J 42385-205	J 42385-201	J 42385-202	J 42385-203	J 42385-204	Thru	Thru