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Boxster & Boxster S (986) Forum 1996-2004

Bolt broke in thermostat housing

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Old 04-29-2023 | 11:46 AM
  #1  
mshenoy's Avatar
mshenoy
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Default Bolt broke in thermostat housing

Hey folks.

I done messed up. I over torqued and broke the bolt in the thermostat housing. It was 7ft pound so I didn’t use a torque wrench at first. Then I filled in coolant and saw a slow leak in the thermostat and figured I used the toorque wrench and that’s when I broke the bolt.

She has been on the Jack stands all winter and I also replaced the water pump. Was so excited to finally be able to start it. But then of course I had to show my rook moves.



see the bottom right bolt in the picture attached
Old 04-29-2023 | 12:00 PM
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Tap and die time. Or go to auto parts store and get a bolt extractor kit. Good luck. Maybe add a little heat with a heat gun to expand the metal when you try to remove it.
Old 04-30-2023 | 06:10 PM
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Relax. It will come easily with an extractor. The threads aren’t under tension anymore and only corrosion is holding it in now. Buy the drill bit that corresponds with the right extractor bit. It’s still not clear to me how you broke it.

Get the made in USA extractor and bits to give yourself the best chance of getting this done. ACE has the Irwin brand.

Last edited by Bush Pilot; 04-30-2023 at 06:12 PM.
Old 05-01-2023 | 12:43 PM
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mshenoy
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Extractor did the trick and a buddy of mine was gracious enough to help.
I was nervous I had ****ed it up beyond repair. Learning a bunch due to these mistakes. Thanks folks




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