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Broken thermostat housing bolt in the block...?

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Broken thermostat housing bolt in the block...?

Old 03-16-2019, 09:51 PM
txcowboy is offline
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Broken thermostat housing bolt in the block...?

Hello all,

I did something dumb, then I went and did something incredibly stupid and now I am praying for a hail mary. I have a 2010 Mini cooper s auto. I have been working on it and because I don't trust dealers and have been working on my trucks my whole life reckoned I could chase down a little coolant leak. Well during reassembly after replacing all kinds of little hoses, clamps, both water pumps, the coolant pipe I did the unthinkable and broke a bolt off in the engine block. It was one of the thermostat housing bolts. It had been off and back in before and so it had looked a little worse for the wear, so I should have known better and got a new bolt. But I was in a hurry because this was the end of my second day on the car and I was hoping to get it back together. Anyhow, the bolt is now broken off just as I got to the 11 ft-lb.

To accelerate from dumb to really dumb, I then drilled the bolt and placed an extractor and promptly broke the extractor off inside the bolt inside the block. I wasn't making any progress even trying to drill out the extractor with a titanium bit. I don't know what to do at this point.

I do have one of those small MAP torches I might be able to fit in there without melting everything else. I also have a Dremel and reckoned on picking up some diamond bits. Does anyone have another or better idea? If both of these options fail and I drill the whole thing out, what is the likelihood of being able to use one of those EZ coil thread dodads successfully? I ain't ever used one of these in a while and it wasn't in something as crucial as this. Thank you for any insight.

Old 03-18-2019, 08:33 AM
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If it was me, I would get a professional involved at this point.
Old 03-18-2019, 09:02 AM
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Bummer! Had a similar story with a bolt that held the AC compressor clutch. Broke off, then broke off the extractor, tried drilling it, everything. Ended up having to throw away a working compressor and replace it. +1 above - I would think about towing it to a good machine shop because you may never get a leak-proof seal again unless that bolt is removed.
Old 03-18-2019, 10:12 AM
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Soak the hole and treads with PB blaster overnight, go back with a small punch(long nose version and cut a notch in the one side and tap it out in a circle, I did this on a bolt once that would not come out when it broke off.

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Old Yesterday, 11:18 AM
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you over torqued is 8Nm or about 6
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