Can somebody PLEASE let me know the best way to get out a thermosat bolt that broke off into my intake manifold. I have about an inch above the manifold to play with? I believe the bolt has been there for 35 years, so it is not coming out to easy. Thanks to anybody that might be able to help.
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Re: bolt stuck in intake manifold - C2
Mike-----
This type of situation is always very difficult. In the interests of not damaging the manifold, I would strongly suggest taking the manifold off of the car (if it's not already) and taking it to a very competent machine shop, preferably one that has EDM (electroless discharge machine) capabilities. They can determine if the bolt can be machined out or if EDM would be the better route. In either case, you will likely have to have the hole drilled and heli-coiled, but that's no problem, at all. You will end up with an undetectable repair that's as strong or stronger than the threads were originally.In Appreciation of John Hinckley -
Re: bolt stuck in intake manifold - C2
If the manifold is cast iron, you can heat the area around the broken bolt and free it up. You can probably turn it out with vise grips, or weld a nut to the end. If there are useable threads all the way to the end, you can double nut the stud and turn on the lower nut.
If it's aluminum, you can still use heat, but you need to be VERY careful and use less heat. I would try just about everything else first, including lots of penetrating oil. The methods of turning the bolt remain the same.Comment
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Re: bolt stuck in intake manifold - C2
Joe, that is good advice. Althought the manifold is still on, it might be the only way to get it out. I might have to try the heating suggestion from Ed first. Thanks for your help!!!Comment
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Re: bolt stuck in intake manifold - C2
Ed, the manifold is cast iron. What do you recommend using to heat it up? If that does not work I might have to remove it like Joe suggested. Thanks for the help. Eventually, I will figure out how to fix these problems myself.Comment
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Re: Bolt stuck in manifold
You'll need a welding torch to do the job... you can try a propane torch, but it may not be able to concentrate enough heat quickly enough to do the job... you need to get it cherry red. I've heard (haven't tried it) that you can touch a candle onto the hot stud, while you're doing this, and the wax will penetrate the threads to help loosen it.
An off-the-wall thought: if all else fails and you don't want to remove the manifold, you could file the broken part down to get a flat top, then use a die to cut new threads on it and use it as a stud.Comment
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Re: bolt stuck in intake manifold - C2
heat the area with a propane torch,then while the bolt is hot drip candle wax all around it. this works as i have taken out the oil galley plugs in blocks this wayComment
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Re: bolt stuck in intake manifold - C2
How about trying the penetrating oil and then using a stud extractor on it?Comment
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Re: bolt stuck in intake manifold - C2
Mike, if you try heat the trick is to heat the surrounding area quickly. I would take the manifold off the car due to fire hazard. If you don't have an acetylene torch, take it to a machine shop. They probably won't charge you much to take it out and they have experience.Comment
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Re: bolt stuck in intake manifold - C2
Thanks to eveybody who has replied to my message. I have decided to take off the manifold and bring it to a machine shop. I rather have somebody with experience do the job. Anyway, this give me a chance to get it sand blasted and repainted.Comment
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Re: bolt stuck in intake manifold - C2
Mike - when you get the manifold home, pay strict attention to ensuring that ALL glass beads are flushed from the manifold before your paint and install it. Sometimes machine shops don't completely spend the time and attention on this, and expect that the customer will do the final prep. Nothing is worse than running your engine and having it suck some glass beads into the cylinders....CraigComment
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Re: Bolt stuck in manifold
If you can weld I can tell you how to get it out properly.
Place a steel washer on the exposed stud, weld the washer to the exposed stud, next weld a short scrap bolt to the washer, while still hot loosen slowly with awrench. This is always successfull!Comment
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Re: bolt stuck in intake manifold - C2
wash it in hot soapy water to break down the static electricty that holds the beads. also remove the oil splash shield from the bottom.Comment
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