Ok this really sucks!

I was replacing the Radiator hoses & decided to replace the thermostat. Broke off the lower bolt to the housing.



I've already tried to use a screw extractor but it must be galled because that snapped off to leaving the tip of the extractor behind.

Time to regroup. Thoughts!

 

This is not going to be easy! I had someone breakan extractor int a 10mm bolt and it took a lot of time and many titanium drill bits to get the extractor out. If you can, use a small drill bit and try to drill around the extractor, but only into the broken bolt and not the T-stat housing. Then when you drilled out as much of the bolt as you can, take a centre punch and try to loosen and remove the extractor. You might have to re tap the housing when thi is all done.
The extractor is very hard so drilling it in nearly impossible. Try the broken bolt first.

Good luck!

 

Hmm, thermostat housing isn't that big of a deal to remove. Personally I would yank it off & install a different unit. I'm sure someone here has one lying around.

 

I agree with Hacker, probabaly best to remove the cross-over and remove the screw while on a bench or just replace. Sorry for your troubles...

 

I'm not too sure of the differences between the 78 and my 87, but I was able to remove the water manifold...but I broke a bolt in the process. If you will be going this route, make sure you replace the 2 small and 1 large o-ring at the base of the manifold.

While you're at it, replact the seal behind the thermostat.

Good luck...

Roger
87s4

 

Start spraying the coolant crossover bolts with penetrant now so you don't snap one of those in a head.

 

Don't jinx the poor guy...

 

I'm warning him in advance to prepare. Would it be better not to warn him and have him snap one that wasn't chemically loosened?

I snapped one, it wasn't too hard to get out. One thing I noticed while drilling it is that one bolt hole on the passenger side and I think one on the driver side go into a spark plug hole. That's good and bad. ou can also twist the penetrant can nozzle into the hole to loosen from the bottom. Make sure the plug hole is plugged to keep foreign objects out.

 

I didn't snap mine off, they were stripped

 

I thought about adding a little comment after my statement reaffirming your recommendation.

Get some Kroil and apply liberally. http://www.kanolabs.com/

 

 

All the credit goes to you... You were the one who told me about Kroil. That stuff is amazing.

 

Man, what a great idea!

Good luck with the water manifold bolts, but the guys seem to have pointed you in the proper direction.

And just for your Eric:

 

Thanks gents. I'm going to keep working on removing the bolt as best I can for now using my Rust Buster. But I've gone ahead and ordered some of that KANO stuff and will start treating the water manifold bolts just in case.

 

Story of my life actually.