While putting in a 160 degree thermostat, I twisted the rear stud off the thermostat housing in the intake. It rotated out about 3 turns and then it locked. I sprayed it with PB Blaster and put it back in. I repeated this 3 times and then attempted to take it out. Well it snapped! I bought the right size easy-out but it so small and the bolt was so tight I'm not at all confident the easy out won't break in the hole. I put my finger in the large hole where the thermostat goes and it is not accessable from there. I feel the only way to remove it is going to be by drilling it. Does the the backside of this stud go to the cooling system or the crankcase? There will be substantial fillings from drilling dropping in the hole. I have never broken a bolt like this and really need some expert advise. I really don't want to pull the intake if at all possible. HELP!!!!! PS there is substantial corrosion( I was running mostly water)(big mistake) in the cooling system and I'm pretty sure that is what cause the bolt to lock.

 

I have got an Idea, tell me how deep in the hole did the bolt break off., 1/8" or so, or did it snap right at the housing?

 

It is sticking up 3/16ths of an inch from the intake.

 

do you have one of those bolt-out removers?

 

Never seen one? I tried to put a vise grip on it but it's too short.

 

I use liquid wrench,( it freed up a frozen hydrolic valve on an old Land Rover bottle jack I had, I had sprayed the valve with every thing else, liquid wrench was the only thing and Vise grips, that opened it ) then use a heat gun to heat up the intake and bolt area, then while its cooling down use the bolt remover(make sure your turning in the right dirction!), bear down and snap that bastard loose.
its already broken, you've got nothing to loose , worst to worst, you can always have a mech, drill it out for ya. let me know.

 

go to sears, craftsman makes them in all sizes you NEED THIS PART, hold on i'll get you a linkfor it

 

go here they work excellent-- http://www.sears.com/sr/javasr/produ...id=00952161000

highlight link and put in your search bar

 

tell me if the link worked

 

I already tried heat. I'm using PB Blaster, not Liquid Wrench. Is it better? I've been told PB Blaster is better. I'm on my way to Sears to buy a bolt out as we speak. Thank you for your help.