i was putting in a 180 thermostat and when i was tightening up the two bolts that attach the coolant hose to the top of the engine one of them snapped. I must have had it cross threaded. There isnt any part of the bolt sticking out so i cant even get it with pliers. I cant drive the truck anywhere because it will blow out coolant everywhere. I dont think i could drill out where the bolt is stuck in because then metal pieces would get into the engine right? I dont know what to do, any ideas?

 

its not an easy job if you have the correct tools to remove a broken bolt . it will have to be drilled out . as for the metal scraps getting into the engine put a rag or tape over the hole. then vacuum the chips away when you are done.
removing a broken bolt takes time .
1. start with a center punch and try to get it as near center as you can.
2. try and figure out what size the bolt is not the socket size but the diameter of the bolt, then get a tap drill chart and find out the tap drill size.
3. start drilling slow with a small drill and put some cutting oil on it i start around 3/16 and work my way up. if its a 3/8 or 7/16 bolt.
4.drill all the way thru the broken bolt it helps relieve pressure .
5. i don't advise using an easy out reason being if you break that your screwed, that is unless you want to grind it out with a carbide dental drill for a couple of hours.
6. after you drill the bolt look and see how close you are to being on center , you should do this while drilling anyways.
7. work your way up to the near the tap drill size, you can find it on the web.
8. OK lets say you drilled it out, now you got bolt threads still in there
9. get a tap and slowly tap it out it might crumble and fall out or it may fight you but it will come out.
10. OK lets say you missed the bolt and drilled way of center now your screwed.

hope this helps and be patient cuz you don't want it any worse than you already have it.

 

as long as i cover up the hole where the thermostat is i shouldnt get any metal in the engine because i think the bolt is encased in the cast iron, i was able to feel under where the bolt is and its solid there. the only problem is, the piece thats stuck in is only like a half inch long. would i be able to drill in far enough to get it out?

 

Drill it as far as you can , you will know when it is thru don't drill thru the casting then you got a new problem.

 

easy outs work great, i guess if ya cross threaded it all the way down ya may have a big issue tho

 

easy outs They work good. May take some work but youll get it. Your not the only to have done this. Drill a hole, get an easy out it will come out like nothing.

 

idk it might be called an easy out, but my dad has this thing that has left handed threads on it and you drill a hole and tread this into it until it tightens up and then it will turn the broken piece of bolt out

 

...yea thats a easy out...or bolt out ect...

 

yea, i would go with the easy out route, cause remember, you got to realighn the mounting holes on that housing onto the engine block, once you get that bolt out, just run a tap through it anyway, clean up the threads

 

yea, im gonna wait till tomorrow before i start screwing around with it. plus i have to go buy an easy out. Its a good thing I have two dakotas.