Big Problem need help

[evilstepdad]

Hello,

Just putting the water pump back on and tightening the bolts, using an old torque wrench my brother had we took the bolts to 25 pounds each and then started doing the sequence again to take them to 40 pounds for each bolt.

Needles to say before we got to the 40 pounds we broke off a bolt, one of the long ones that go's back into the aluminum housing that bolts to the block.

Has anyone had this happen and how did you get it out. It is broke off pretty deep inside of there.

Thanks,

evilstepdad

[bigwhite7.3stroker]

Dang man that sucks hope you get it figured out and here's a bump....

[bigcountrysg]

Does it leak? I hate to sound like this but if it is not leaking. Then I wouldn't worry about it. How ever I would get it to a machine shop so the bolt could be extracted and a new one installed.

[sflem849]

Have you removed the water pump again (I know that sucks...but it probably has to be done) With that knowledge you may be able to weld a nut on the end or get on it with a visegrips. If I had to guess it is broke flush with the block though.
I have not had my water pump off yet so I don't know exactly how it is set up.

[willholl79]

probably gonna have to take the front end (grill, radiator, etc) off to get to it and either try and ez-out or drill the bolt out and re-thread the hole.

[evilstepdad]

Don't know if it would leak. Only got to that bolt to start taking them to 40 pounds and it broke, took the pump back off right of way to see what I could do. That part of the pump sets on a aluminum housing and it is broke down inside of that on the block. Nothing is even close to showing.

[bigcountrysg]

Originally Posted by willholl79

probably gonna have to take the front end (grill, radiator, etc) off to get to it and either try and ez-out or drill the bolt out and re-thread the hole.

Your gonna have to remove the grill, core support, radiator, intercooler, a/c, and then your gonna have to remove the front engine plate to get to that bolt. Lost of labor hours wrapped up for this repair.

[evilstepdad]

Thanks for all the answers. Is there any place I can go to that will show me how this stuff comes off, especially the front engine plate.

Thanks again,

[sevenmalards]

To get it off you could TRY some waterweld or J.B. weld (waterweld is a lot more solid)

J-B Weld Company - WATER WELD Product Information

This is what I would do first, it might save you a big headache of tap & easyouting the bolt.

Take the pump back off, and if you have to take off the grill and accessories then so be it if you need the room. Look at the broken bolt and align it with the broken one in the block (so the pieces fit together) mix up some waterweld and put a small amount (so it doesn't ooze out and get on the block, but stays in between the two bolts) You might want to experiment with a different bolt so you get the amount down. Once you get the amount down mix a new batch (hardens in about 10 min.) line the bolts up and put the waterweld on the bolt in your hand then line it up and stick it in the hole, keep some pressure on it so you know it's contacting the inner bolt.
Here is the hardest part. You will have to wait (I'd wait 24hrs) then go out and see if you can back it out with a ratchet and socket. Chances are you will. I used waterweld to hold in a sparkplug in an old subaru and it lasted TWO YEARS until I sold the car.
Good luck,
Take it SLOW!

You can also use some sort of lubricant on the outside of the bolt going in (just don't get it on the weld spot) in order to help the waterweld to not adhere to the block if some should ooze out.

[evilstepdad]

I guess I am going to try a reversible drill bit first so my question would be, what kind of a drill bit would be the best one for this? What brand is a good quality brand that might be up to the task?
Thanks to all,

evilstepdad