Series 3 XJ6 Broken thermostat bolt
#1
#2
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.
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.
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Grant Francis (05-25-2016)
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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!
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!
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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
#11
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
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
#12
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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
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
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davidboger (05-28-2016)
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