While R&R the sway bar brackets on the 240 for the umpteenth time I stripped one of the bolts and the captured nut. Did some reading and it appears the options are drill and tap new threads, or install a Helicoil kit. I like the idea of the Helicoil as I have extra bolts of the same M10x1.5 size and would like to keep the same, although it's not a deal breaker to have to go with a larger bolt. Any thoughts on which way I should go, I am guessing that to do the Helicoil needs a complete install kit for $$$? From searching it looks like Acklands and Fastenall sell kits?

Properly done a helicoil works well and you don't need to worry about an over size bolt. Going with the over size bolt and nut may bring in the problem of the nut fitting into a possibly confined space, not sure how much room you have to fit a larger nut.

It's a captured nut with no access inside the frame rail. I've never done this before so I was reading that the existing nut could be drilled and tapped out to the next size and use the next size bolt? The Helicoil sounds better but not sure that the cost of the complete install kit to do one is worth it.

Drill and tap it larger...if you want it stock, bring it over and I'll weld it up and you can do it all again (minus the stripping part ).

Thanks Craig, yes stock would be preferable. Should be OK to drive with 3 of 4 bolts in place??

As long as you're driving nicely.