I am trying to get a new thermostat in my Vette. Problem is that I was trying to be delicate but one of the bolts stapped. Suggestions? :cry :cry

 

Do you know if it snapped klean at the manifold, or is some sticking out?

 

There is some sticking out. I am trying to get the forward one off but without any luck. Each of them is soaked in penetrating oil. I may have to cut the forward one off in order to have two studs.

 

You need an "Easy Out"
An easy out is a "drill bit looking" device that will bite into the broken bolt as you rotate it counterclockwise into a small hole that you need to drill into the center of the broken bolt with a hand drill or Dremel tool. You should purcahse a small Titanium drill bit; size (7/64..I think). Drill into the center of the brokem bolt only approx a quartetr inch deep. Then screw the easy out into the hole counterclockwise and it will remove the broken bolt. Let me know how it goes or if you need more info.

:flag :cool: :thumbs:

 

broken bolt or stud removal is one of those things that the procedure is never the same.
it all depends on so many factors like how much is sticking out,type of fastener material,type of component materialmwhat all resources you have on hand....
assuming you have equipment and theres a bit sticking up heres what i'd try.
if its threaded into cast iron just heat up around the stud with a torch then put a piece of ice on the broken part for a sec .
you can usually get em out with your finger this way.even broken exhaust studs.
if that doesnt work, next set a nut over the broken part and weld it to it with an arc welder (pref wire feed),then use ice and a wrench.
in an aluminum part i wouldnt resort to heat methods.
if those arent an option,use the penetrant, (like you said you did),(kano is the best ive found).
use a very small hammer,the smallest you got,rap the top of the stud with short fast strokes to jar it,then tap it around side to side.
if you see it distorting the top your hitting it to hard. and do not hit it to hard sideways.just a light tap with a very small hammer.
you may get it out with pliers at this stage. an automatic centerpunch works great for this too.
if you still havent got it at this point (or if nothings sticking up) you probly need to drill and blast.
your main thing here is getting the pilot hole centered for the easy out.
you need a small good shape centerpunch-sharp,a good quality, american made easy out (more flutes the better-dont try a square one).
go buy just the single easy out,best you can find.if you break a cheapo off your gonna need a torch.
before center punching for the drilling (start small like the above post said),try and get the top of the broken piece flat.
use a file on it or tap it flat with the hammer.
now carefully centerpunch it,start light so you can check if its in the center,then tap it in good.
drill the pilot plenty deep.
take the bolt size to the hardware store with you and find a sales dude that is knowledgeable about tools,they should set you up with the right sized bit and extractor.
oh and use a tungsten bit like stated earlier,it may be a grade 8 bolt but probly is 5 since it broke off.
good luck,they can be dicey. patience and coolheadedness will prevail!
:cheers:
oh yea-that second one your trying to get,just rap straight down on the head a few times,then use a wrench and try tight then loose alternately,a little more each direction,then more tapping till it gives.if it starts coming loose then tightens as your backing it out then go back in with it a bit and then back out....more lube-keep working it.....


[Modified by mitymek, 10:46 PM 7/16/2003]