Hi All,

I was trying to change the thermostat when I broke off one of the bolts.
(Top right, long one.) I' think it might go into the manifold/water rail.
Has anyone got any ideas?
Any help would be greatly appreciated.

Many Thanks
Geoff

 

Lots of alcohol, for YOU.

Remove the cover, file that broken bit flat faced, centre pop it in the centre, obviously, drill it through, then a bigger drill bit, then a bigger one, and so on, until you have only a shell of that broken stud remaining.

Drink some more.

Carefully chisel out that shell, and if you have consumed enough, the threads are probably OK.

If for some strange reason the break is NOT almost flush with the rail, heat the protuding piece up, HOT, and vice grips just MIGHT get it out.

I have never been that blessed.

Anti-seize on the replacement, and repeat in 20 years.

 

Hi Grant,
Thanks a lot for that, I'll have a drink and think about it.
Cheers again.

 

Welcome to the club of XJ6 owners that have experienced broken thermostat housing bolts. No fun, lots of patience in getting out, sometimes heat needs to be rendered, lucky ones drill and use easy out. Mine were never just drill and get out, lots of chiseling, etc. Good luck!

 

Mine was protruding about 3/8" I got it out by filing the end until it had 2 flat sides. Got a hold of it with Vice grips. Lots of pb blaster, and some heat. I was amazed (and thrilled) it came out. You have a chance........ but for sure, any scheme requires drinking.

 

If the hole gets hopelessly bollixed up there's enough 'meat' to simply re-tap the hole to the next larger size--- 3/8-24 in this case.

Not that I personally have ever ....um....er ....ahem.....bollixed up a hole trying to remove a broken bolt, mind you.

Nope. Never. Not ME

Cheers
DD

 

I forgot.

DO NOT use an "Easy out" here, coz if that sucker breaks, and they do, you will be in more strife than Ned Kelly on a bad day, and alcohol will be of NO use.

The next size is also one I have done a few, well many, times to get going.

 

So my '82 runs cold on cool mornings sometimes. I assume a sticky thermostat.

I do not wish to join your club or receive your newsletter.

Should I do more than PB Blaster soak and hot engine for the initial loosening? Any other advice?

Thanks!

 

The bolts are long and horizontal so three's little hope of any aerosol actually getting down inside the holes

Just go slow and keep working the bolts back and forth, IMHO


Cheers
DD

 

Thanks a lot everyone,
I'll let you know how I get on.

 

Surely there is a breaker near you that has a pile of them...
I keep them on hand just for that purpose. I figure the meager price of them is less than the time invested in trying to fix an old one... Of course I'd be glad to help, but since I'm in the US, shipping charges would likely be more than the part...

David
shop.EverydayXJ.com

 

David:


Only you. Most breakers just bust these engines into
piles of alloy and steel and off to the furnaces.
But, removing it for better access seems worth the effort.

Geoff:


I've never been "lucky" enough to bust a fastener and have a stub
to find a way to bite on. I do have a clever socket with many slender rods in it. something on the order of the fabled Chines finger puzzle.
Just press it on and twist the harder one twists the tighter the "fingers' grab. ,I've removed slotted screws with "bollixed" slots.
Thanks, Doug, I like that word!!!


Heat. Very useful.
1. Anneal hard steel for drilling.
2. Break a corrosion bond.
3. Expand the surrounding metal, so as to lessen the friction.


Once on the bench and vertical. and, f you have welding equipment.
Weld on a nut. It may take several efforts. Heat plays a part here as well.


Caveats:


1. No EZY outs.
2. If you drill, use sharp bits and don't be timid in the force.
3. Use Antiseize on the new fastener.


Luck is always good.
Carl

 

Thanks very much everyone.
I was getting nowhere so I took Grant's advise and got drunk.
Not sure what happened but the bolt's out.

 

Those Aussies! If there's an easy way, they know it! If there isn't one, they Invent one!
(';')

 

Well done.

We have the technology, usually in a bottle, with a cork in the top, and we do NOT over think things, ruins the allocated drinking time.

Best part about our fixes is, WE SHARE IT AROUND.

 

!!!!!


All right! Two thumbs up!!!


Carl

 

A 3/8" drive air wrench works too. As the wrench impacts the soaked bolt and moves it in micrometers rather than the manual force of a human hand on a socket or wrench which uses more continual force and breaks the bolt.

 

Among my pending projects is to replace my thermostat (not closing).
Having heard about how easy it is to break these bolts - I did some research and found a really helpful video on some tips.
1) Slowly loosen and tighten to get started - if that's not working, heat with torch. Use penetrating oil after every movement of the bolt. Back and forth is best
2) When you've loosened up the first one, tighten it back up and go to the second one. He said the main reason people break off bolts is the impact of the uneven forces as you remove the bolts. If you have two bolt off and one tight, the angle on that last bolt is much more likely to break it. That was the best bit in the video. Really helpful advice for me.

 

^^
Old Farmer trick too.
(';')