Uh Oh... snapped thermostat housing bolts.

[RustyA]

Have to agree pulling the intake might be best way to get clear access in van situation. Hard to see and get good line of sight for drilling and extracting.

 

[ruffdog]

Yeah, vans are fun as the thermostat is right under the windshield. Time to clean the floor and pull the dog house so you can get close and personal with it. If you have transfer punches, you might be able to use the t-stat housing to get the bolts center punched accurately. Take the effort to center punch them the best you can. It could be worse....like exhaust manifold bolts.

 

[ultrarunner]

I do have transfer punches... never occurred to me.

 

[Mat4644]

Did the bolts deteriorate in the thermostat housing or just so rusted in they broke?

 

[ultrarunner]

Twisted off a little above manifold level when attempting to back out.

Looks like they sheared instead of rusting... one bolt is a double bolt with hex in the middle as GM uses to mount A/C brackets/accessories

Maybe a good thing the housing is solidly attached because it will make a guide...

 

[dodge man]

Helicoil come with a drill bit to drill the threads oversized. My experience is if a bolt is broken off, not from stuck threads an easy out, left hand drill bits etc will get it out. If it’s because it’s stuck and rusted in place, time to start drilling.

 

[Richard]

Buy a new vehicle?? That fixes several things....fixes your broken bolt issues, gives you a fresh oil change, new air filter... perhaps a win/win!??

 

[ultrarunner]

Kind of at a crossroads on property management... the last few years life is taking care of mom with Alzheimer's and my hospital job...

It would take a lot of work to install a generator, piped air compressor, custom Tig welded aluminum shelves, welding tanks, dual battery inverter, ambulance high output alternator, suspension mods, aux fuel for lawn/garden tools, custom slide out threading vise... etc.

Annual mileage around 3k the last few years... but having a fully equipped mobile workshop has been invaluable over the decades.

I'm sure it will be on the road again but State Smog testing is the elephant in the room...

 

[shovelmike]

Might be easier to help knowing what engine and what manifold. guessing 350 4bbl cast? Green coolant and again assuming the coolant wasnt serviced every couple years.
are the bolts broken above the manifold or below?
Since both broke they are probably rotted.
access really doesnt give you any control of drilling them out.
pull the manifold, replace or send to a machine shop.
Bet I'm not wrong.

Pulling the intake manifold might be the best plan of action here given limited room to drill.

 

[ultrarunner]

I filled the thermostat housing bolt "Wells" with Kroil...

No rush if it takes time to work magic...