Today me and my friend took everything apart. Tore out the intake manifold, the alt, the compressor, water pump pretty much everything. Well were still trying to find out where the leak of coolant is but it definitely isn't looking to good. I've got quite a few pictures but the worst thing is the bolts at the front of the intake are rusted to the point of breaking. I was able to get one bolt out but the other bolt broke inside of the head and left barely 1/4 inch in the open. It's all just really not looking to good. Posting pictures up now.







Notice how the bolt broke at the tip... There is so much rust and corrosion it's ridiculous.


I'm curious as to what this is though. I have a feeling I need to replace it because it wouldn't come out so we tore it up pretty good.

 

well, i'm on my work email so i can't view your pictures, but i can offer advice on your broken bolt...lots of pb blaster and a easy out kit. if you can't get a grip on that little bit thats sticking out, then see if you can't easy out it.

 

ok, don't panic.
the broken piece is just the coolant temp sensor. not expensive.
all the broken bolts will need to be drilled out, and then an ez-out or 'extractor' used. some people will recommend left hand drill bill, but that's really not necessary. just use a punch to get a small bit started, then a little bigger bit, then an ez-out. don't break the bit off in the bolt, or it gets harder.

 

To get the bolt out you have to use a special kit that drills it out (easy out kit I guess it's called). The electrode is probably your temp sending unit if it was around the thermostat. Also, why did you let the engine get that bad? Don't you know you work so much easier with a clean engine, and you get no rust build up also?

 

As I just did this not 2 days ago and ran into the same problem with the bolts what i did was drill them out so an easy out would fit but before using it i heated the bolts with an oxy torch just make sure you don't melt anything

 

Well in response to your response I had no idea about ANYTHING about these trucks. Just recently have I actually learned about all the problems these trucks have and I have the forum to thank for that. I have been doing the needed maintenance, had the radiator flushed, the transmission flushed, oil has been done every 3 months with 10w30, have used octane booster and injector cleaning fluids once a month (possibly overkill) rear end has been recently redone to the 4.11's (guy that had my truck before towed a 10k boat with this poor little truck). I've owned it for about 2 years, and not this year have I been learning the ropes at DIY's and getting the courage to actually get under the hood and do my own work rather than taking it to a shop. I've bought the Hughes book and read through it at least 3 times just trying to get myself familiar with these engines. I'm proud of myself that I was able to do all this as is lol :P

 

i've seen worse.
have you got a drill? ease-outs ?
you don't need a torch, that's just asking for more trouble.

 

Like Vaughn said don't panic. Only breaking one bolt is a check in the win column. it would be a good idea to replace that temp sensor anyway.(the plenum is off, so why not). Also before assembly, get your hands on a good tap set and chase all the threads out, especially when the broken bolt was. Chase the ones for the thermostat too. Clean up as much of the area and the parts as best you can before putting it all back together. It will make it seem to go easier with clean parts. Also, if you do develop a leak anywhere afterwars you'll be able to spot it earlier.

 

Using a map gas torch won't melt anything and will get the head more than hot enough to help with the bolt removal. Heat the head and not the bolt. If you heat the bolt it will become soft and malleable and will break even easier than it is now. Heating the head will allow expansion of the parts easing removal of the bolts. Make sure you are centered perfectly on the bolts and drill straight down into them. You don't want to damage the threads of the head or you will have alot more work ahead of you.

 

Ight cool thanks for all the help you guys you have no idea how much it helps .