[olddog]

Thanks guys.

I managed to get 3 of the Heli-coils out by screwing the bolt down until it tuned hard (1/2" rachet), then turn the bolt back out and the heli coil would back up a couple threads. Then I could turn the bolt in a couple more turns and I would hit the hard spot again and repeat. This would get about 8 threads up out of the hole, and then you could spin the bolt down with your finger and there was no hard spot any more. At this point I could grip the heli-coil with pliers and then turn the bolt. This got them the rest of the way out.

I think the factory did not run the tap down far enough, causing the bottom of the heli-coil to be tight (slightly smaller ID).

The fourth hole the bolt could be turned all the way in and it wouldn't get tight enough to move the heli-coil. So I ran a tapered tap down thinking it would bugger it up enough for the bolt to grip it. This time the tap actuall cut a fine piece out of the heli-coil. I ran the tap up and down a dozen more times and now the bolt spins free in it. So I'm leaving well enough alone.

I'll get a heli-coil kit tomorrow (correct tap) and put new heli-coils in. I ordered a stud kit. I'm going to try that route.