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Old 03-18-2013, 07:18 AM   #1
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Thermostat Housing

Ok Guys just wanted to share something with the forum. For all you old timers with lot's of wrench time this will be a laugh for you.

For all you new timers with no wrench time like me it may save you alot of cussing, whining, crying, even some money.

Do not over torque the thermostat housing bolts they break! And when they break it is never as easy as grabbing the broken end with some pliers or vise grips and backing it out. You either need to weld a bolt on the end which I can not do since I do not have a welder.

Or you have to drill it out and use an easy-out that hopefully does not break if you have the cheap one from Lowe's they break get rid of them.

Or drill and re- tap.

Right now I am in the cussing wish I had read the torque settings correctly phase. 156 inch pounds of torque is not foot lbs! Not that I got any where near 156 foot pounds before it broke the bolt anyway!

Every step forward is greeted by 5 to 10 steps backwards I just about had it ready to drive.

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Old 03-18-2013, 09:24 AM   #2
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Great post THANKS for the heads up. This is great info!!!

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Old 03-18-2013, 09:36 AM   #3
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You can try putting jbweld on a nut threading it on the broken bolt and let it set. If you have enough bolt sticking out, do this with 2 nuts and put your wrench on the inside nut... Usually works...
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Old 03-18-2013, 10:51 AM   #4
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Yea thats the same for valve cover bolts etc. they all break if you over torque them. once you have enough wrench time you should be able to tighten bolts without the need of a torque wrench.
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Old 03-18-2013, 11:03 AM   #5
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Thermostat housing

I tried the JB Weld stuff let it set overnight says it only needs 15 hours let it set for a complete 24 hrs at an average temp of about 50 degrees.

It came right off as soon as I pulled on it at all.

So I am going to try drilling it and tap I center punched the broken bolt
and will drill a small pilot hole of about 1/8th or less fist then drill bigger till I can get either a torq bit or easy out in it and back it out.
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Old 03-18-2013, 11:08 AM   #6
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sounds like you didn't mix the jb weld in the correct proportions because the jb weld shoulda stuck solid.
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Old 03-18-2013, 11:13 AM   #7
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just thread a nut onto the bolt so that there is a little thread sticking past the nut. Then take a pair of vice grips and crush the threads. That way the nut can not spin back off the bolt, and it will force the bolt to turn...
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Old 03-18-2013, 11:33 AM   #8
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thermostat housing

I thought I mixed it well it was all one color dark grey?

Did it like I do epoxy all the time. But never used JB Weld before so I could have gooned it!

and the bolt does not stick far enough through the nut to be able to crush threads with vise grips though I like that idea for the next bolt I break probably tonight!

I am actually considering the 4.0 head swap onto the 4.2 base and then I get Fuel Injection and an extra Horse Power jump.

Seems silly to do that for a broken thermostat housing bolt though.
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Old 03-19-2013, 07:46 AM   #9
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Thermostat Housing

Ok so thought I would share an update on the busted bolt.

Took the entire front grill off so I would have plenty of work room to get to the bolt.

Word to the wise when you do this make sure you center tap the broken bolt you do not want your drill bit wandering on you. Hit it hard a couple of times with the hammer and a tap with a good point that makes a solid indent sorry to be so descriptive but do not want to leave any minor detail out. Once you have the pilot hole drilled things go well from there slowly increase the size of your drill bits till you have drilled out the bolt to wear you can remove it or re-tap it . If you miss hitting the center do not freak out you can over drill the hole as a last re-sort and put a thread repair insert.

Guess what this knucklehead did last night! Both freaked out when I over drilled it then calmed down and bought an insert.

For those that are interested the bolts are 5/16ths - 18 which is coarse threading the small bolt is 3/4ths length and the long one is 2 1/2.

I am going with Stainless steel to avoid rust and will be putting loctite on them it may be over kill but at this stage in my build I am not looking to replace the head.

Let me know old timer wrenches if this newb is doing anything dumb at this point.

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