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Broken thermostat stud 700

After some digging I didn't see any mention of my current predicament.

While removing the nuts on my thermostat housing, the top nut took the end of the stud which is threaded into the head along with it. There is about 1.25" of stud still exposed but no threaded area left.

I made a spiffy pic and labeled it but being newbish I am not entirely sure I have gotten the upload system right. Lets hope so!

Being a bit inexperienced with these kinds of problems I am coming to you folks first because obviously the consequences are pretty bad if I botch this. Yes, the amount of stud exposed is a positive thing but the stud is pretty rusty and it was pretty weak to have failed already. I noticed leaking signs (aside from the rust) around the thermostat seal on the side where the stud snapped. Since the "oh $#!t" moment I have hit it with PB blaster, waited 10 mins, then heated it lightly with a propane torch for a few cycles.

Here is the catch obviously. The stud could likely be seized in the head and I could really be screwed if I leave absolutely nothing to work with in botching its removal.

Anybody get them selves out of this situation without catastrophic problems? Is there another solution available like maybe threading the remaining stud down further and milling down the thermostat body to lower the overall bolt location?

Im a little nervous here folks, somebody talk me down please!

Bruce







THREADED THREADED EXPANDED FLAT PRINT ALL
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New Broken thermostat stud [700]
posted by  duce1  on Mon Feb 28 18:38 CST 2011 >


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