Problem Installing Roush Hood Strut Kit

[ECSIII]

There’s no problem with the Roush kit but rather with Ford’s assembly of my 2022 GT convertible. The problem arose because there’s a new part to be added beneath an existing bolt. See the attached picture captured from a Roush “how to install” video. The red arrow is pointing to the bolt that in the original configuration is securing a brace to the flat part of the upper strut mount. That brace appears to be holding the silver component (see the green arrow) in place. By the way, what is that silver part with the black lines attached to it? When removing the bolt it felt like it was binding and coming out at a bit of an unexpected angle. And indeed that was the case. The hole for the bracket does not align well with the threaded hole for the bolt and the threads were damaged on both the bolt and the part into which it screws. It seems that in the original assembly someone forced the bolt in, no doubt using a power tool.

I’m now trying to figure out how to remedy the situation. I’ve thought of a couple of alternatives but am anticipating knowledgeable forum participants will have better insight. My thoughts have included first to somehow wedge the bracket such that the holes align (they are misaligned by about 1/8”). Then try to insert a new bolt with good threads. If the receiving threads are too damaged then carefully try re-threading them using a new, previously unused tap. Another thought has been to simply enlarge the brace hole only enough to fully expose the receiving threads. I mention this latter point because so far I’ve not seen a way to force the alignment of the brace hole and keeping it in place while reassembling with the Roush part inserted. For whatever it’s worth in helping to make suggestions, the damaged, original hex head bolt is an M8 1.25 and 25mm length with a “dog point” tip.

Looking forward to receiving input on how best, including the easiest way, to fix this problem.

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[ECSIII]

Got it fixed! After anguishing over the matter a lot, decided to try “wedging” the offending bracket into proper alignment with the bolt hole in the upper strut mount. My greatest concern was the potential to damage the silver color component with the black lines attached to it that the bracket supports (still don’t know what that part is). Anyway, the alignment effort worked.

The next step was to very carefully clean up the threads on the bolt hole using a brand-new tap lubricated with WD-40 and that was followed by a refresh of the threads on the bolt with a new die. That too proved to be successful and the Roush lower support piece put in place and the original OEM bolt reinstalled.

The wedges were removed and the remaining steps of the installation were completed without any further surprises or mishaps. The Roush hood struts are a great improvement and in that respect make the raising and lowering of the hood extremely easy while also getting that awful hood prop bar out of the way.

By the way, here’s another question. I noticed in a number of pictures of various GT engine compartments that models earlier than my 2022 had what look like yellow vinyl covers on the hood release latch. That latch is a hateful thing to operate trying to get one’s fingers into the narrow opening and shoving it to the left. Seems like that bit of vinyl padding on the lever could be useful. Can it be added for the 2022 model year latch lever?

 

[Rapid Red]

Wood is the great persuader, good thinking.

 

[Mike Pfeifer]

That silver part is the valve block for the stability control system.

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