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Thread Stripping (Tensile Shear Failure) What happens: The internal or external threads shear off completely, leaving a smooth, hollowed bore. This happens when mechanical forces exceed the shear strength of the material—most commonly when a hard steel bolt is over-tightened into soft aluminum. Common areas of failure: Aluminum oil pan drain plugs, aluminum transmission casing threads, and cylinder head bolts. The Fix: Adhering to exact torque specifications and using solid-wall stee …