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CrewedBlue
Dodge Dakota
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6/22/2003
16:36:27
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 Subject: HELP!! Removing broken bolt!!
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I am in desperate need of some help removing a thermostat housing (bottom) bolt on a 4.7 whose head broke off when I was trying to remove the housing. There was about 1/4" of "stud" out of the block when the housing was removed, but that has dwindled down to nearly 1/8", due to the fact that it keeps breaking off when I try to loosen it.
I have tried WD-40 w/ vice grips, and heating the block and using vice grips but neither have worked. The position of the bolt makes it nearly impossible to drill it out straight w/out removing the radiator to get a good shot at it.
Any help would be greatly appreciated!!!
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juniordork
Dodge Dakota
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6/22/2003
16:44:22
|  RE: HELP!! Removing broken bolt!!
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Message:
thats what you get F^#kin with it should have left it alone
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mag762
Dodge Dakota
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6/22/2003
17:47:42
|  RE: HELP!! Removing broken bolt!!
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juniorDORK, I doubt thats the kind of response he was looking for, try to grow up before make a response like that to someone needing help.
CrewedBlue, maybe you can soak the bolt in some kind of penetrating oil and try to carefully back it out with a pliers. If that dousnt work you could cut a slit in the bolt and use a screw driver to try and back it out. If none of this works you might just have to remove the radiator like you said to get a straight shot at drilling it out. Hope this helped.
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jviper
Dodge Dakota
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6/22/2003
21:37:40
|  RE: HELP!! Removing broken bolt!!
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Message:
if the broken end still has some threads on it try putting a nut on as far as it will go, then find some one with a welder and tack weld the inside of the nut to the bolt. i had to do this to my header bolts when 3 of the heads broke off
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Chris
Dodge Dakota
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6/23/2003
08:10:40
| RE: HELP!! Removing broken bolt!!
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Message:
This happened to me as well, I had to use vise grips, heat, penetrating fluid for about 2 hours to get mine out, I found that by driving it in a couple turns (would go in easier than out) I could get the penetrating fluid in there and slowly get it out. Ihope by now you have it out and back together though...
I found myself biking the 2 miles to the store to get a new bolt as my wife was working the day I did this...
I have also ehard candle wax will pull into things like this or header bolts but have never tried it myself.
Make sure you use antisieze when it goes back together...
Chris
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nate
Dodge Dakota
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6/23/2003
10:57:34
| RE: HELP!! Removing broken bolt!!
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If it comes to drilling, go ahead and get some left hand bits and a set of eaz-outs. worth the money in reduced effort now and in the future.
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Merlin
Dodge Dakota
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6/23/2003
11:22:34
| RE: HELP!! Removing broken bolt!!
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jviper has the solution. If the threads are too mangled for a nut to screw on, get a slightly larger nut that will go over the existing threads and weld the inside of the nut to the broken bolt. Then use a socket or a box wrench to back it out. I'm a retired maintenance machinist. I've done this many times.
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RTSpeeddemon
Dodge Dakota
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6/23/2003
11:34:29
| RE: HELP!! Removing broken bolt!!
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Merlin is correct!
Weld a new nut on top of the existing broken bolt and it will turn out easily.
Make sure you place a large washer around the surrounding area to prevent you from welding onto the housing itself.
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jviper
Dodge Dakota
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6/23/2003
11:58:43
|  RE: HELP!! Removing broken bolt!!
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Message:
Weld a nut onto it, why didn't I think of that !
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yup
Dodge Dakota
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6/23/2003
14:12:11
| RE: HELP!! Removing broken bolt!!
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Message:
Welding the nut should be the solution, but if you have to drill, maybe someone you know has a 90 degree drill. I've got a cordless Makita that is perfect for situations like this. Reverse drill bits are good for backing the broken bolt out of the housing.
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tek
Dodge Dakota
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6/23/2003
15:09:04
| RE: HELP!! Removing broken bolt!!
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Message:
Welding another nut is a good mecahnics trick if you have access to a welder and sometimes works..
Sears is advertising a new device looks like a socket but has reverse teeth made to bite into a stripped nut, for removal. Its kinda the oppisite of an ezy-out, (why didn't I think of that idea), maybe/maybe this will work.. I don't believe in miricale stuff "as seen on tv" but craftsman is usually pretty good stuff, and I would give it a try.
After that the cleanest method is remove the raditor, reverse drill bits and the easy out it is about your only choice.
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Scojodak
Dodge Dakota
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6/23/2003
17:38:41
| RE: HELP!! Removing broken bolt!!
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Drill a hole in it BEFORE welding the nut. It will help the bolt loosen up.
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Ditto
Dodge Dakota
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6/23/2003
17:55:05
| RE: HELP!! Removing broken bolt!!
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Message:
try welding a nut to the threads that are left
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Crewed Blue
Dodge Dakota
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6/23/2003
18:36:28
|  UPDATE
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Thank you to all who posted suggestions. Most will go in the mental inbox for future reference.
I ended up welding a 4" piece of flat bar w/ a hole drilled in one end to the remnants of the bolt. This provided a handle to turn the bolt. I sprayed some WD-40 and tried to turn the bolt in and out, which seemed to be working until SNAP! The bolt finally broke off further into the threads.
Luckily this bolt hole (bottom) goes all the way through the mount for the thermostat. I took the "easy" way out and removed the radiator. Then drilled the hole out to accept a 1/4" bolt w/ a nut & washer on the backside.
Put everything back together w/ antisieze on the top bolt. Filled the radiator and let'er run for a while w/ no leaks. No leaks today, so I think I am in good shape.
Thanks again for all the replies.
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MonkeyPox
Dodge Dakota
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6/23/2003
19:43:38
|  RE: HELP!! Removing broken bolt!!
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man I'm glad i'm not in the market for a used dakota
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yup
Dodge Dakota
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6/23/2003
21:17:05
| RE: HELP!! Removing broken bolt!!
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Message:
Bolt must have been totally bottomed out in the hole for it not to come out easy after all that work.
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Seeee
Dodge Dakota
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6/23/2003
21:20:19
| RE: HELP!! Removing broken bolt!!
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Message:
see u didn't listen to us so y did u ask
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