i was putting my new performance thermostat into my 02 5.9l, and broke one of the bolts holding down the thernostat housing down off into the intake. I am wondering if anyone had any ideas, or a how to of the removal, and the install of a new intake manifold.....

 

Well, if the other half of the bolt is still in there, you can drill into it, then use an extractor (aka ez out) to get the bolt out. Otherwise, you pretty much have to unhook everything from the intake manifold, then unbolt it from the heads.

 

yea i tried one of the biggest ez outs that would fit it, and broke it tring to get the bolt out... so i guess i am buying a new intake manifold and installing it myself, which is why i was wondering if there was a how to,or maybe from a CHILTON manuel.

 

Well, if you can manage to get the EZ out out of there you can always drill it out and put a helicoil in it. Your pretty much stuck trying to drill through that EZ out though.. they are brittle but very hard. Definitely use a torque wrench next time to tighten down such bolts.

 

Not only torque wrench but anti-seize is your friend. Have you tried a small butane torch with an EZ Out? I have a Hemi, so I can't remember what the 5.9 intake looks like.

 

The Magnum intake is similiar, but the bolts are different as they go straight up and down into the heads like an old 426 hemi instead of the classic small block angle. I have a copy of the 01 manual, the 5.9 section should be the same so far as the engine itself. Problem is, how do I get the necessary pages to you?

 

Here's a link to download the 2001 FSM:
http://www.summitvista.com/hemi

 

All good answers to an incorrectly phrased question. The only opening to the intake is the air horn on top, the hole you dropped the bolt into is the water passage. You probably won't have a problem with the remains unless it drifts down and blocks a passage or is forced out into the water pump. As for removing the broken stud... (see the other answers and be prepared to drill, allot!) good luck.

 

The thread is over 5 years old, I think he got it by now...

 

^^^^ lol