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Broken bolt on thermostat housing (but it's worse than that!)
This is a 2000 F150 5.4. I am mechanically inclined but I am not a mechanic. So read this understanding I was doing the best I could, which has been inadequate to this point. So no need to criticize my approach. I will concede it has not been effective So what had happened was...I was changing the thermostat and the bolt for the housing broke off below the surface (could not weld a nut to the top). I started with the typical approach. I used "PB Blast," drilled a hole into the bolt, inserted an extractor, heated with a torch, attempted to remove and the extractor "BROKE OFF IN THE BOLT!" I tried every drill bit I could find (Titanium, Cobalt, etc.) and I could NOT drill the extractor out. The drill bits hardly scratched it. Soooo... I took a grinder and removed some of the intake crossover tube (on the outside, not to comprise the tube water flows thru) so I could then grind the bolt down "below" where I "thought" the extractor was in the bolt. That was a success. I was able to drill into the bolt again and insert and extractor. This time the top of the extractor broke (square part I had a crescent wrench on).
So this is where I am now... and I will post an embarrassing picture of it. The extractor bit is still in the bolt. I bought a hefty pair of vice grips (needed one anyway), I also bought a "bolt and stud extractor." I'm hoping one of these will provide enough grip to turn it. I feel like this is sort of my last chance before I have to take the entire intake off.
My questions are here.
1. Is the vice grip \ stud extractor a good next step?
2. Can I still use this intake\crossover tube, as long as I did not damage the inner part where the housing seals (don't care about the aesthetics) ? Or am I looking at replacing the entire intake regardless?
I would appreciate your help!
Kevin
Your seeing the extractor bit. The actual bolt is mostly below the grinded part. This is the bolt and stud extractor I bought...
I'd be concerned the seal would leak if you succeeded in getting the bolt out.
Clean the metal chips out of the alternator and from the pulleys.(Use rag on parts that you don't want metal chips in next time).
Install this: PLEASE make sure it's the correct part.
I wouldn't do anything to it until you have a different manifold to bolt in its p[lace. You've already destroyed the sealing surface where the gasket has to hold the pressure from the heated coolant. Should be able to find one at a junk yard from reasonable to cheap.
Thanks... yeah I was fatigued and frustrated by the time I pulled the grinder out. I should have covered everything. Thanks for the part number. My understanding is I would need to take the entire intake off to get the bolts removed from the crossover tube. At this point, would you recommend replacing the entire intake?
YES...its dead! The amount of work required to "save" that intake exceeds buying another one ($80 replacement vs $300 for welding machining time) You only need the coolant crossover!! If for some reason the remove the entire intake...
...replace the heater hose TUBE that runs under the intake manifold!!! if it doesn't leak YET...it will. btw there is a thread on here about doing that exact thing. also changing to a HOSE instead of a metal pipe that rusts out.
should NOT need the entire manifold.....however.....your coolant crossover is DEAD. remove it form the manifold then see what you can do with the manifold....before getting one.
should NOT need the entire manifold.....however.....your coolant crossover is DEAD. remove it form the manifold then see what you can do with the manifold....before getting one.
Hello, please HELP
I haven't gone as far as the above. I have not damaged anything further than.....I broke the bolt off, on the right side, adjacent to this example. It is too deep to use any extraction methods as you know.
I have taken all the bolts out that I can see surrounding the body of the coolant crossover, but it seems very stuck in place. I'm sure there's more I'm missing.
Can you provide a link,on how to do this? I can't seem to find this on YouTube. Only how to change the thermostat, but not what to do when the bolt breaks when putting the housing back together.
Want to hear something crazy! I put it all back together with just the one remaining bolt, and I've been driving it for almost 5 years! From what I can tell, it hasn't leaked a drop. I'm not recommending anyone else do it, but if your situation allows you to dance with things implausible... 😂
For me, it's a work truck (extra vehicle) with well over 300K miles. Every day it runs, is a gift!
Broken bolt on thermostat housing (but it's worse than that!)
So what had happened was...I was changing the thermostat and the bolt for the housing broke off below the surface (could not weld a nut to the top). I started with the typical approach. I used "PB Blast," drilled a hole into the bolt, inserted an extractor, heated with a torch, attempted to remove and the extractor "BROKE OFF IN THE BOLT!" I tried every drill bit I could find (Titanium, Cobalt, etc.) and I could NOT drill the extractor out. The drill bits hardly scratched it. Soooo... I took a grinder and removed some of the intake crossover tube (on the outside, not to comprise the tube water flows thru) so I could then grind the bolt down "below" where I "thought" the extractor was in the bolt. That was a success. I was able to drill into the bolt again and insert and extractor. This time the top of the extractor broke (square part I had a crescent wrench on). 
