Humvee Thermostat Housing Problem

[Hummer Guy]

Today I went to install the thermostat on the humvee and realize yesterday that I snapped the bolt head off, now I just got threads sticking out. The question is, can the whole thermostat housing on the engine be changed easily?

Taking off the broken bolt is the last thing I want to do; I already needed a breaker bar to just get the bolt to turn before the head snapped.

 

[Thumper580]

A small (8") pipe wrench and some heat may do the trick.... It's worth a shot at this point.

 

[GopherHill]

In the future, use heat and an impact gun for a steel bolt in aluminum.

 

[Hummer Guy]

A small (8") pipe wrench and some heat may do the trick.... It's worth a shot at this point.

That's going to be one of the things I try, my next plan is to cut a slot with a Dremel in it and try a flathead on a breaker bar. If that fails, Im going to to sqaure it off and try a pipe wrench

 

[Hummer Guy]

In the future, use heat and an impact gun for a steel bolt in aluminum.

So that's what my plan was but it was too tight to squeeze an impact on it, so I put heat on it and used a breaker bar and then snapped the head

 

[86humv]

I might have one to sell

 

[papakb]

Soak the threads with Kroil or some other penetrating oil for a couple of hours before you co on to the next step. When you install the new thermostat make sure to use some anti-sieze compound on the threads.

 

[87cr250r]

You snapped it while installing? You should be able to remove the remains with a pair of pliers.

 

[Coug]

You snapped it while installing? You should be able to remove the remains with a pair of pliers.

Looks like he went to install, then realized/remembered that it snapped it off during removal.

 

[Retiredwarhorses]

Ok, never use an impact wrench
you have corrosion that’s preventing this bolt from coming out, luckily you have enough to grab via vise grips, you want to start my soaking it in penetrating oil, then hit it with a propane torch, let it cool for 10mins, hit it again with heat, get a good grip on the bolt and start try to turn it…there is no more tension on the bolt threads because you broke the head off.
also, make sure someone didnt run a stud all the way through because they stripped the threads out previously and there is a nut on the back side, seen it many times.

 

[TOBASH]

Don’t just twist counterclockwise. Twist clockwise occasionally to loosen crap stuck in the threads, just as if you were to tap a thread.

 

[GopherHill]

That's going to be one of the things I try, my next plan is to cut a slot with a Dremel in it and try a flathead on a breaker bar. If that fails, Im going to to sqaure it off and try a pipe wrench

Be careful. Use a penetrating oil soak then heat then more penetrating oil. Don't get too much twisting with a breaker bar.

 

[Hummer Guy]

I might have one to sell

I'll message you if everything else fails

 

[Hummer Guy]

You snapped it while installing? You should be able to remove the remains with a pair of pliers.

Snapped it while removing it, I used the biggest pair of pliers I possibly could and couldn't get it to bulge any

 

[Hummer Guy]

Ok, never use an impact wrench
you have corrosion that’s preventing this bolt from coming out, luckily you have enough to grab via vise grips, you want to start my soaking it in penetrating oil, then hit it with a propane torch, let it cool for 10mins, hit it again with heat, get a good grip on the bolt and start try to turn it…there is no more tension on the bolt threads because you broke the head off.
also, make sure someone didnt run a stud all the way through because they stripped the threads out previously and there is a nut on the back side, seen it many times.

Yep, I checked that, there's no bolt in the back

 

[Hummer Guy]

How does the housing come off? I figured that if I removed both of the bolts from both sides, it'll pop off, but the side closer to the driver side don't want to come off

If I had the housing off, I'll be able to get my torch on it better and have a better grip with some pliers on a vice

 

[Hummer Guy]

Well, that didn't work, I tried drilling it out but looks like its still stuck, I may just drill a hole and use a nut and bolt

 

[Maxjeep1]

Well, that didn't work, I tried drilling it out but looks like its still stuck, I may just drill a hole and use a nut and bolt

Weld a nut on it.

 

[87cr250r]

If you have a hole through it you can use an EZ Out. Put it in your oven for 20 minutes at 300 degrees and then use the EZ Out while hot. Don't force it, it should come out with modest effort. You don't want to break the EZ out.

 

[osteo16]

Wow, and iI thought disasters only happened to me.. Glad Im not the only one this crap happens to

Drill and re tap... Just dont over drill the old threads..

Id nut and bolt it though.. Save about 3 hours of your life youll never get back ...