Thermostat housing broken bolt

Discussion in ''Da Nailhead' started by Brickwhite, Apr 28, 2021.

  1. Brickwhite

    Brickwhite Well-Known Member

    What's the best method to remove a broken bolt from the thermostat housing.

    -I'll try some heat, penetrating oil and vise grips first.. the move on the the welder....

    Is the bypass is cast iron?

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    the thermostat was pretty old and not closing/opening all the way.

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  2. TrunkMonkey

    TrunkMonkey Well-Known Member

    Yes. The crossover manifold is cast iron.

    Whack the broken shank with moderate force a couple times, then lay a nut that fits on that broken shank and weld it, and as it turns back to dark cherry red, work it back and forth with a wrench, or with impact driver on low setting forward and reverse.

    If you don't have the means to weld it, you might want to pull the manifold and get it to a shop that can remove it.

    Does not look like enough to get a good purchase with vice grips.

    Galvanic corrosion may make it almost impossible to remove by drilling and using an EZ Out extractor.
     
    322bnh likes this.
  3. Brickwhite

    Brickwhite Well-Known Member

    I had enough old bolt to weld a nut to the top, I broke the weld 2 times before it came loose.

    Made sure I tapped both holes again before re-assembly.

    Thanks for the advice. I always hate drilling and tapping old bolts.

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  4. TrunkMonkey

    TrunkMonkey Well-Known Member

    Same. :D

    Glad you were able to get it.
     
  5. Max Damage

    Max Damage I'm working on it!

  6. Brickwhite

    Brickwhite Well-Known Member

    After breaking the first 2 times I welded the nut I don't think that tool would have been tight enough... she was in there...
     
  7. Max Damage

    Max Damage I'm working on it!

    Certainly possible... It does tighten as you turn it counter clockwise, but I have broken off some other stumps with it too, and ended up drilling...
     

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