I am trying to install a starter on a 2010 Subaru Legacy (one of the easiest projects you can do on this car short of changing a tire). As I was re-installing the long bold (see photos), I turned the bolt in by hand 1/8 of a turn the bolt grabbed a thread and just got harder to turn. I backed the bolt out and found shavings on the bolt. The starting threads on the bolt was goofed up. Thinking that I had cross threaded the bold, I put a tap on the bold to clean up the threads. Getting the bolt started was still tough, but easier than before. WTF!
It seems that the bolt hole threads are crossed. I have taps and dies, but the taps are not long enough to reach the threads in the block. I am putting oil on the threads of the bolt and giving the oil a change to clean out the threads, as if I was using a tap. The photo of the bolt is how it looked after my last session of gently easing the oiled bolt into the bolt hole threads.
I know I should be using a tap, but standards taps are not nearly long enough for the depth of the threads at this location. Amy suggestions? Is what I am going making things worse? Just trying to get this thing done, but the car is fighting me every step of the way.