My thermostat was stuck open so I am in the process of replaing it but while removing the two bolts bolting it to the motor one of them broke off. Anybody got any ideas on how to remove broken off bolts?

 

buy a tap and thread kit. that sux.

 

no worries...
you'll need to drill out the center of the broken bolt, and then use an 'extractor' to remove the remainder. try real hard not to break a drill bit off in the bolt, as that just makes it that much harder. start with a small drill bit, about 1/8 - 3/16. you'll need good, sharp drill bits. don't try to use old worn out junk or you'll be there foreever. if you're lucky you'll get the broken bolt out w/o damaging the original threads. as you drill out the center, the old bolt will sort of give up the fight. but if you do mess them up, then drill/re-tap the next larger size.

another option other than ease-outs is left handed drill bits. but i like std bit and ease-outs better.
http://www.harborfreight.com/cpi/cta...emnumber=40349
http://www.harborfreight.com/cpi/cta...emnumber=38180

 

Thanks for the help, I purchased some of them extractors, My only worries are being able to fit the drill and drill bit down far enough to drill into it straight. Cause if you've ever noticed the thermostat is kinda deep in there, with all that other stuff in the way.

 

yep. you'll have to uncover the area as necessary. see the plenum and thermostat diy at the top of the 2nd gen. you may have to remove the alt and/or ac comp to make room. on the ac comp don't take the lines off, just unbolt the mounting and swing it over to passenger side out of the way.

 

Yup.... you'll be amazed at how much that area opens up with all that stuff out of the way.

I would not even attempt to drill out that bolt without doing what dhvaughan mentions.

If you fail... you will be replacing your intake manifold which I just finished doing. It sucked... fought me every step of the way....

 

Alright then, sounds good. Thanks for the insight

 

I agree, DO NOT try to do that without first removing the ac, alternator, and accessory bracket.

Even IF you were able to drill a straight hole in that bolt, you will need to be careful with the extractor.
They are VERY hard, but that also means they are brittle, make sure you are not wiggling around when you are turning it. You definitely dont want that breaking off in the bolt, cause you wont be able to drill it out.
Just happened to me a few weeks ago when working on my quad, luckly I still had the head of the bolt to work with.

 

Okay so, I have started drilling and it seems that my tools arent what I need. When I drill at thebroke bolt allthe bit does is spin on top of it and do nothing. So what kind of drill bit do I need??

 

Are the bits new and sharp?

Titanium coated would be nice.