Broken Bolt...Argh!!! - JeepForum.com
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post #1 of 16 Old 04-26-2015, 12:39 PM Thread Starter
boone
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Broken Bolt...Argh!!!

Hi Guys,

I was working on changing the thermostat on my 2003 WJ with a 4.7L when the bottom bolt for the thermostat housing broke off. I have nothing to grab onto with a Vice-Grips since the bolt broke off inside of the block. Check out the pic. Any ideas as to the best way to get myself out of this mess?

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post #2 of 16 Old 04-26-2015, 12:46 PM
mr312712
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Drill It out but your probably gonna mess up the threads.

It doesn't matter If the guy next to you doesn't know your racing winning Is winning.
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04 WJ Overland Inferno Red 4.7 MAGNUM V8 HIGH OUTPUT
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post #3 of 16 Old 04-26-2015, 12:58 PM
JMZ101586
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Have two choices

Femove the rad and everything else in front and drill it out

Or

Remove the timing cover and drill it out Unless you have an angle drill and VERY good hands drilling without taking stuff out is gonna be damn near impossible.

On the plus side at least the lower bolt goes all through the housing. The upper doesn't.

04 WJ SE 4.7 Powertech
98 Camaro SLP SS
06 Pontiac GTO
20 WK2 Overland 5.7 Hemi
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post #4 of 16 Old 04-26-2015, 01:02 PM Thread Starter
boone
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Thanks guys. Sounds like I'll be doing some drilling. The radiator is out already. So, at least that part is done.
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post #5 of 16 Old 04-27-2015, 11:06 PM
HVACNY
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Im feeling your pain.My bolt head snapped off the outer cover.let us know how it turns out.

2000 Jeep Grand Cherokee 4.7 V8

2013 Jeep Grand Cherokee Overland 5.7 Hemi
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post #6 of 16 Old 04-28-2015, 06:38 AM
MadderThanMax
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Get Some PB Blaster down there & let it soak, then apply a little heat and you may be lucky that it comes out when applying the drill to it. Hopefully you have a drill that can change to anti clockwise and it it just "may" unscrew what's left...
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post #7 of 16 Old 04-29-2015, 08:56 AM Thread Starter
boone
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I have some left hand drill bits coming on Friday. We'll see how things go.
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post #8 of 16 Old 04-29-2015, 11:41 AM
Double E
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On the back side, can you dremel-grind a line into the housing that also reaches the bolt and allows you to turn it out like a screw?

"We have it totally under control. Itís one person coming in from China. We have it under control. Itís going to be just fine." ~D. Trump, Jan 22, 2020.
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post #9 of 16 Old 04-29-2015, 12:12 PM
new2site
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Autozone has USED kits you can "buy" and then return for full refund...their policy...the "buy" part is apparently because people put down stolen/ fake credit card for collateral.
http://www.autozone.com/test-scan-an...bolt-extractor
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post #10 of 16 Old 04-29-2015, 03:42 PM
doityourselfMM
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How did it snap? From over torqueing? The reason I ask is, I wonder if it will turn freely, or if it is binding? If it turned freely, put a small dab of JB Weld on the end of another bolt, push them together, and let it harden overnight. Obviously, using too much JB could cause it to ooze into the threads. I'd even push a small piece of rubber tubing into the hole to keep the cement out of the threads. The rubber tube would help to keep the outer bolt in place while the cement hardens.

Crazy idea, I know!
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post #11 of 16 Old 05-17-2015, 06:13 PM Thread Starter
boone
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After tying everything under the sun to get this broken bolt out, I finally just had to bite the bullet and replace the timing chain cover. I picked up a used one on eBay for $65.00. I hope that I can save someone some pain with this little tip. If you are going to replace your thermostat, spray some PB Blaster in the little hole that the lower housing bolt threads into on the back of the timing cover. I don't know why Chrysler designed it this way but that open hole just leaves a way for moisture to get in there and freeze up the bolt.
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post #12 of 16 Old 05-18-2015, 09:42 AM
Cleaner13
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I will say this, after changing mine out recently, that housing is only like 8ft/lbs of torque to tighten

2001 WJ Limited NV247 4.7
2008 WK Limited NV245 3.0 CRD
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post #13 of 16 Old 05-18-2015, 10:02 AM
99WJ01TJ
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For those uninitiated to the V8 thermostat bolt breaking(I was definitely in the club) the lower bolt will not easy out once its corroded in place. I tried even with the timing cover off. That's why I replaced mine when it snapped off, it was only $80 for a used timing cover. Would've run me about $40 to have a shop drill it ant re tap it.
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post #14 of 16 Old 09-28-2017, 09:29 PM
Tumanyan
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The old wound bleeding again!
I had a 01 GC 4.7, went trough this broken thermostat bolt crap years ago.
Now, on my "new" 04 Overland, servicing the cooling system, it's deja vu again.
The lower bolt, of course, again.
It was protruding about 1/4 or so, so i made a flat screwdriver slot in it with dremel.
Then i made the mating male part to it from grade 8 M6 bolt.
Another piece, a 1/2 long bushing with M6 tread inside was screwed over this two mating pieces
to insure they stay together, when torque applied to unscrew the broken part.
The broken bolt was just like fused/welded with that aluminum timing cover, because even soaking it
with PB blaster and DW40 overnight did nothing. It just broke again.
So, long story short, I took apart the front of the Jeep, drilled out the broken bolt,
run a M6 tap trough it, and put stainless bolts instead.
What a waste of time!
This is soo lame, instead of having bolts on the top and the bottom, they could place them on the sides, and the bottom bolt would not be in the harms way, like it is now.
Or just use stainless bolts.
I posted this, because someone else will go through this for sure, thanks to Chrysler, and I hope this helps.
And, yeah, having to deal with same problem twice, i needed to let the steam out:-)
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post #15 of 16 Old 09-29-2017, 07:58 AM
Double E
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Amen brother. Maybe some anti-seize will help out too. I'm not looking forward to this repair on one of my WJs for certain. I might just spray it down now and at every oil change till I have to go after it some day.

"We have it totally under control. Itís one person coming in from China. We have it under control. Itís going to be just fine." ~D. Trump, Jan 22, 2020.
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