So I took of my Thermostat Housing and Replaced thermostat no problem Then as I am putting in the bolts (hand Screwed them in to start) I am ratcheting down my last bold ant Boom The bolt Broke off inside the Block...... WTF

Any ideas on How to Fix other then Pulling the Motor out and Using my tapset to bull the screw out and retap?
Here are some Pics..

Yeah Yeah I know the bolts Look old but hey I couldn't Find Replacements and the other two went in FINE

 

Take off the cover and see if there is enough bolt to grab it with some vice grips. If not, you won't need to pull the entire motor, just the water pump housing and extract/drill/retap as needed.

 

keep in mind alum. doesn't need much torque to be held down, remember the bolts also need to expand with the heat , etc.

 

LOL FTW!
I love it when people do that, you over tightened it! lol

 

After you EZ out the thing, or replace your water pump housing, remember to put Anti-Seize on the threads on the new bolts!

 

in order of ease:

1) vice grips if you have enough room on the broken bolt head
2) replace the housing, no need to pull the motor out. you can find a housing in the for sale section
3) spot weld onto the bolt in housing and use vice grips to back it out. if you have a welder then replace this with #2 on the list.

after you're done go get a set of metric taps and dies and tap out your housing threads, this is not done as often as it should be.

 

Replace Housing it is lol .. Tried Drilling it out and Re-tapping yeah .. Drill bit Broke off inside.. FML lol

 

Don't worry I made the same mistake when I replaced my waterpump as preventative maintenance during my vacuum hose job. I snapped 2 bolts off wondering what the hell is going on and cursing up a storm. After reading the factory manual (which should have been step 1 ) I read that it only needs to be 6 ft lbs MAX. Any tighter and.... SNAP!!!