I broke off a bolt trying to change thermostats. It has about
a half inch sticking out, the rest is still in the intake. What is the best removal procedure?

 

If its got a 1/2 inch sticking out, you should be able to turn it out with some vice grips.
Hit it with some penetrating oil first, and dont totally torque on it, just use the grips if it will turn out.

 

if not try a crap load of pb blaster and a pipe wrench. i've had alot better luck with a pipe wrench than with vise grips.

 

Thanks for the input guys. I do appreciate it.

 

FYI be very careful and take your time. I had to repair a base where someone had broken that bolt off and tried to drill it out. He failed and I got it for cheap on Ebay

I'd say you could also lightly heat the area but I'd be wary of doing that.

David

 

Since you have about 1/2" sitcking out you can try to file the bolt down square, until it matches a wrench perfectly and then just wrench it out

 

I would go vise grips first... then pipe wrench (I haven't had luck with those though) then use an ez-out. Soak the bolt with WD-40 either way.