Broken water pump bolt. - Mustang Evolution

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Old 05-18-2014, 12:00 PM   #1
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Broken water pump bolt.

Wile removing the water pump I ran in to a bolt that felt cross threaded. After spraying with PB Blaster, tried to take the bolt out and it broke. What are some good safe way's to get the broken part out of the block?
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Old 05-18-2014, 01:39 PM   #2
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What you’ll need to remove the broken bolt

Electric or air drill

Drill bushing.. something like this Drill Bushings | MSCDirect.com
This centers the drill bit in the housing bolt hole so you don’t get off center and damage the water pump, timing cover housing or engine block

5/32” Cobalt coated bit

EZY-OUT Screw Extractor Bolt Extractors | MSCDirect.com

Long shank 5/16-18 tap .. a T handle tap wrench will make things easier when turning the tap


Removing the broken bolt

1.) Remove the water pump, fan, fan shroud & radiator – you’ll need lots of room to get the drill positioned straight.
2.) Test fit the drill bushing in the timing cover housing – this assumes that the bolt broke off below the surface of the housing. If it is too loose, use some scotch tape wrapped around it to make a snug fit. The drill bushing helps center the drill bit up on the broken bolt so that it does not get off into the timing cover or engine block. If the bushing does not fit at least 3/8” into the timing cover, you may want to consider removing the timing cover and attacking the remnant of the bolt shank with a propane torch and Vise grips. If not, then find a drill bit big enough to drill off some of the remnant of the bolt shank until you can get the drill bushing in the required 3/8” or deeper into the timing cover housing. You will end up using the timing cover housing to center the large drill bit on the broken bolt shank. This is not the best plan, since the aluminum timing cover is soft and it would be easy to get the bit off center and damage the timing cover.
3.) Once you have the drill bushing in place, chuck up the drill bit and drill the broken bolt. Use lots of WD40 to cool the drill bit. If you break the drill bit off in the bolt, it is time for a tow trip the automotive machine shop. Drill bits and easy outs are extremely hard and cannot be removed by ordinary means. It takes a solid carbide bit and extreme care to remove a broken drill bit or broken easy out.
4.) When you have drilled about ½” into the broken bolt, then remove the drill bushing and use a hammer to tap the easy out into place. Then chuck up the easy out in a T handle tap wrench. Turn the tap wrench slowly counter clockwise and you will feel it dig into the broken bolt. If it starts to slip, tap on the tap wrench with the hammer to reseat the easy out into the bolt.
5.) Keep turning and one of three things will happen:
a.) The bolt will come out and your efforts will be rewarded.
b.) Or the easy out will continue to slip and more efforts will not make it grip. This means you get to remove the timing cover and attack the bolt remnant head on. That means you get to drill the bolt out to a thin shell & either re-tap the hole or install a helicoil threaded insert.
c.) Or worst of all, the easy out will break off it the bolt shank. Then it is tow time to the automotive machine shop and pain in the wallet.
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Old 05-18-2014, 02:19 PM   #3
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Awesome, That's what I call in depth help. Thanks ALMOST STOCK. Already have all the stuff of the front, and for that matter the top of the block. Doing a cam, head and intake swap. Also the bumpers are off and the radiator is out, so I have plenty of room. Again thanks.
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Old 05-18-2014, 10:23 PM   #4
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Stick a nut up against it and hit the inside of the nut with a MIG. Be careful not to weld the bolt into the block obviously... just tack it. Heat the thing up with a torch after letting it soak and gently back it out.
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Old 05-19-2014, 12:11 PM   #5
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Quote:
Originally Posted by scottydsntknow View Post
Stick a nut up against it and hit the inside of the nut with a MIG. Be careful not to weld the bolt into the block obviously... just tack it. Heat the thing up with a torch after letting it soak and gently back it out.
Bolt was broke off flush with the timing chain cove. Had to heat and pry the cover to get it off the bolt. Somehow the bolt broke again flush with the block. Once off, found another bolt broke flush with the block on the same water outlet. Both broken bolts are on the #1 cylinder side. Kind of burgard up the timing chain cover wile prying it off so will have to get another. Ordered the stuff from the link from ALMOST STOCK and will use the old cover as a guide. Sounds like a good plan but as everybody knows, who knows.
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