Dimensions, drill sizes and wrench sizes for #4-40 UNC.
Designation
#4-40 UNC
Major (outside) diameter
2.845 mm · 0.112"
Pitch
0.635 mm · 40 TPI
Pitch diameter
2.432 mm · 0.0958"
Minor diameter (external)
2.066 mm · 0.0813"
Minor diameter (internal)
2.157 mm · 0.0849"
Recommended tap drill
#43 · 2.26 mm · ≈71% thread
Clearance hole
Close #30 · Normal #27 · Loose #17 - nominal + 1/64" / 1/32" / 1/16" to the nearest standard drill (common shop practice).
Socket key (across flats)
3/32"
Close #30 · Normal #27 · Loose #17 - nominal + 1/64" / 1/32" / 1/16" to the nearest standard drill (common shop practice).
Tightening torque estimate
SAE J429 tabulates grades from 1/4 in upwards, so no proof load or tightening torque is published for numbered sizes.
Put #4-40 UNC on a job sheet
The bolt schedule collects the fasteners for one job onto a single sheet - tap drill, wrench size, grade and tightening torque on every line, taken straight from pages like this one. Free schedules hold 3 lines and are saved in this browser only.
For a #4-40 UNC thread, drill the hole with a #43 tap drill (2.26 mm) before tapping. That produces roughly 71% thread engagement, the usual target for a strong, tappable hole. The mating bolt has a major diameter of 2.845 mm and a pitch of 0.635 mm (40 TPI).
To pass a #4-40 UNC bolt through a part rather than thread it, use a clearance hole: Close #30 · Normal #27 · Loose #17 - nominal + 1/64" / 1/32" / 1/16" to the nearest standard drill (common shop practice)..
All values are generated from the standard thread formulas (ISO 68-1 / ASME B1.1) and published standard tables - not hand-entered. See the full reference.
Frequently asked questions
What drill size do I need to tap a #4-40 UNC thread?
Drill #43 (2.26 mm) before tapping #4-40 UNC. That leaves roughly 71% thread engagement, the usual target for a strong hole that still taps cleanly.
Is #4-40 UNC a coarse or fine thread?
#4-40 UNC is a Unified coarse (UNC) thread at 40 threads per inch, the default inch series for general fastening in this diameter.
What size clearance hole does a #4-40 UNC bolt need?
Close #30 · Normal #27 · Loose #17 - nominal + 1/64" / 1/32" / 1/16" to the nearest standard drill (common shop practice). A clearance hole lets the #4-40 UNC bolt pass through the part instead of threading into it.
What is the pitch diameter of #4-40 UNC?
The pitch diameter of #4-40 UNC is 2.432 mm (0.0958"). It is the diameter where the thread ridge and groove are equally wide, and the reference dimension for checking thread fit.
Nearest standard metric sizes by major diameter. These are substitutes by size only - the thread forms are not interchangeable, so never run one into the other.