Thermostat bolt broken
 

I overtorqued the lower tstat bolt and managed to shear it off when removing it. There is a portion of the bolt left in the housing that is sticking out, probably about 1/8". If tried to remove it with vice grips and a punch & hammer, after pb blaster was applied. Still haven't removed it. I may try and easy out next. Does anyone have any other suggestions to remove this?

Pull the water pump and then you can drill it out.

I'd try the easy out if you have enough room to drill.

I would just replace the water pump. You can get a new one at any auto parts store.

Heat

Good advise, heat the housing around the bolt just before you begin to use the easyout

Steve

:iagree:

Aluminum will expand more than the steel bolt when heat is applied.

Heat, PB Blaster, new Vice Grips, time and patience.

I would weld a nut on it before drilling since there is a little stub still sticking out. The welding also heats it and helps loosen it.

you can get a brand new water pump for $140. :smash:

I just checked Advanced Auto and they have a new one for $120. Swap it out and be done with it.

Why replace that pump so soon? With a little time and patience, the broken bolt can be extracted.

To me, it seems like an easy challenge to keep $120 or more in your pocket.

I did exactly this yesterday. :banghead: What did you end up doing to solve the problem?

A1 Cardon water pump. Rock Auto under $90,also at
Rock Auto, Bosch OEM replacement water pump $110 if this the route you decide to go.

The broken screw was completely swaged in there and I couldn't get it out with the tools I had so I just bought a new water pump. I tried pb blaster, vice grips, pin and hammer, welding a nut (i'm a beginner welder) once I pulled the pump. The new water pump was $110 off amazon. Good luck.

If your mileage is around 50k to 65k, just replace the water pump. The effort to drill and tap will take more time and money. If your around the mileage I've stated, you will have to replace it anyway, it is very easy to replace the water pump on a LS1. I even posted a trick to help hold the gasket in place in the forum (General).. Put a rubber band on all three of the bolts and install the gasket on, the screws spread out and hold the gasket in place just prior to bolting it up to the block.. I know it will make sence when your doing it.