broken bolts, water inlet

[twall64]

last night I was going to remove the aluminum water inlet from the intake manifold so I could drill and tap for a 1/2 inch NPT fitting for a temp probe. I was proud of myself for getting everything together before starting the job like a new thermostat, gasket, sealer, drill and tap and expected to be finished and at home for the debate on TV. Using a short handle ratchet I tried to ease off the bolts and with very little force the first one twisted off, then the second one as well. I tapped on the housing with a hammer to loosen it and removed it without problems then cleaned the area around them. I got some 3/8 nuts and placed them over what was left of the bolts and welded them together. I gave them a minute for the heat to move into the manifold and put a socket on them and they came out with little effort. I had also used this method before on the front of the engine when I had to remove the timing cover and it worked flawlessly.

[MadMaxetc]

The heat from welding will help break the rust bond, so don'
t just tack the nut on. Turn up the heat and let her fly!

[ICEMAN6166]

then of course you used anti seize on the new bolts so this would not happen again
i hope.

[Alan Mclennan]

OK! I`ll say it!........Nice work Twall!!

[twall64]

I think the previous owner used low grade bolts. They did not snap when they broke they just twisted around and broke.

[bird55]

good job!
my situation is always a bolt upside down and in some place I can't get into or something. And I don't own a welder either!. And it seems like they break off flush. Never much fun. Ever.

[olliesshop]

Nice trick ...