Hey guys, just wondering if anyone has any suggestions for getting a broken thermostat housing bolt out? I drilled it and used an easy out, but broke the easy out, so now I guess I am just down to pulling the intake off, and sending it to the machine shop.
When it gets back I am going to put studs in and use nuts on the top so I do not have this problem again.
Just curious if anyone had any other ideas?

 

Done this once. Had small piece sticking out of intake, took it to work and fit a nut over it, tig welded it from the inside of nut, the heat expanded the metal and turned it right out with a cresent wrench.
Bob

 

You have a few other options for removing the broken bolt.
You might be able to cut a slot in the broken bolt and remove it with a screw driver or you could just drill it through completely and put a helicoil in the manifold ,which is most likely what the machine shop will do.

 

The same thing happened to me. There was a piece of the bolt sticking out of the intake manifold so I just filed down two sides and turned it out with vise grips.

 

You say you broke the easy out... did it break off in the bolt? If so, its made of hardened steel, and the only way to drill through it is with a diamond tipped bit... I made the same mistake, and had to have a shop do it for me.

 

Hey SSC
Thats the best signature I've ever read!
Bob

 

I just had the bolt brake on mine a few weeks ago. I was already pulling the intake to do a cam swap. I also broke off the easy out in the bolt. What I did was get a carbide endmill bit from work, I forget what size. I have a small Craftsman drill press in my garage. I carefully centered it and cleared the bolt and easy out from the manifold. I was then able to go back and retap the hole with the original size threads, no heli coil required.

 

Hurt,

I'm guessing that you have the E-Z out stuck in there as well. If you can grab an end of the extractor ant twist it out, you'll be lucky. If not, you might be using carbide or an EDM/tap burner to get out the extractor, either of which will require you to remove the intake.

If you get lucky or not, you might need or want to install a thread repair insert. Instead of a Heli-Coil, consider a solid insert, since they are a lot stronger and just as easy to install:

 

I drilled mine out and retapped it. Manifold was off the car. Good luck

 

Sometimes you can blow an easy out out with a cutting torch. Can be a little tricky, when the easy out is out, then you can drill it out and retap the hole. Had a bolt brake off in a brand new manifold last time. Pissed me off cause I was trying to fix a leaky housing before they closed the shop at work. I get off at 5 and they close at 6. 5:30 and I had a broken bolt!

 

hey hurt.......are you from springfield? i was just at NAPA on saturday and my buddy JB was working on a TBI manifold with a bolt broke off in the t-stat housing hole. if it is yours i wouldn't worry. JB is very capable at what he does and he was makin good progress when i was talking to him. should be good as new.

 

If theres a small bump on the part stuck in there, maybe you can stick in a punch (on the outer edge) and hit the punch w/ a hammer as if to turn the whole thing in the hole and unthread it out. That might work but maybe not if the bolt's rusted in there (which is probably why the bolt broke in the first place .)

 

Hey guys thanks for the advice.
No I am from Columbus to answer your question......
I just thought it was funny how I called the guy at the machine shop, and told him only about the bolt problem, and he asked TPI? I just started laughing.
Sorry guys I am new at this, I am a former Stang owner, and never encountered some of the problems I am having here.

The whole reason for the IROC is I got so sick of hearing all the Mustang guys talk all the crap, so I figured I would beat them with a car they think is inferior.

OK enough of that, the intake is coming out tomorrow, and hopefull the guys can get it done, and my heads done in a couple of weeks, and soon I will be back on the road.

Thanks guys!

 

Good luck.I too was a Mustang guy at one time. My 87 GT Mustang never would handle like my 89 GTA. Mustangs are cheaper thats why people drive them. Welcome to Third gens.

 

ok, deja vu. First the bolt broke off in the thermostat housing, then the easy-out broke off in the bolt. Actually, I managed to get the broken easy-out out of the bolt by welding a nut to it. The weld wouldnt stick to the bolt, but it stuck to the easy-out. Then i ended up drilling the bolt out anyway, and helicoiling it.

 

Dont forget to put plenty of Anti-sieze compound or Thread sealer on those puppies when you put them back in. It's nice when you don't having to dork around with rusty/corroded bolts next time you go to take that part off.

Remember: Breaking a bolt is bad luck. Breaking the same bolt twice means you're an idiot. I'm an idiot

 

Once again guys, thank you for the advice.
I am just now going out to take the intake off, and send it to the shop. You know I couldnt stop there, so I am doing a timing gear drive (unless anyone has any advice against that) cam swap, valve job, just because I am paranoid about the head gaskets, I dont know maybe that is a Mustang trait I am left with. The shop is also going to do the intake work to the upper.
Well I guess i am just hoping for the best.

Thanks again guys!

 

Do yourself a favor and get a quiet gear drive..... That damn whining gets old REAL FAST.