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broken bolt inside block... bolt was holding bracket holding thermostat to engine... 700 1990

posted by  Aye Roll on  Sat Mar 1 14:20 CST 2003
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last visit: Tue Oct 14 21:08 CST 2014
[RELATED]

"You might explore the possibility of drilling out the stud and tapping the resulting hole if it is just slightly bigger than the current stud. You might find a fractional size that would be a little bigger than the current metric."

And if that doesn't work, there are "stepped studs" available at good autoparts dealers. Any NAPA should carry these. The idea is that it's an M8 thread for the part that goes in the block, then an M6 again out where it sticks out. We used to use these all the time to deal with VW exhaust studs- notorious for breaking in the head. It's tough to accurately drill a steel stud out of aluminum, especially a small one. The starting hole is all-important, so make absolutely sure it's in the center of the thing.
Another *great* tool for removing this type of problem is a reverse drill bit.
These will walk a broken stud right up out of a hole when they bite in. Really neat tool, may be a bit hard to find but beats the hell out of an Easy-out which IMHO has about a 50% failure rate.

For anyone attempting this kind of repair- GOOD LUCK!

--
Rob Bareiss, New London CT ::: 86 244DL, 87 244DL, 88 744GLE, 91 244: 808K total






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