Disaster

mikes93sedandeville · #1 (**permalink**) 01-02-07, 04:27 PM

On my 89 SDV with 4.5 the top torx head bolt on the water pump was sooooo tight no tool on earth could remove it. So I ended up grinding the head off to remove the pump. At any rate all that is left is a nub and I tried using and easy out to remove it. The bolt is so tight that nothing and I mean nothing will break it loose. What can I do to get this fixed? Can I just put it back together and tighten the other 2 bolts around it very tight and hope for the best? Am I looking at removing the engine just to get it right? I can't drill the bolt out because of the angle( so it looks) and if i do get it our would a helicoil work?

illumina · #2 (**permalink**) 01-02-07, 04:46 PM

Well, you need to try and get that remaining bolt out some way. You shouldn't have to pull the engine, but you will need an angle drill fitting (can't remember what they're called, but I have one) to get in there, drill a hole and try a wizzy-out.

Try hosing the bolt area with PB Blaster (gobs of it!), let it sit, and apply the wizzy-out (called an easy-out for most

) after a while. You'll want to drill as deep as you can to fit the thicker part of the wizzy-out inside the bolt so you minimize the break-off factor, which is easy to do with wizzies. For the wizzy-out, you should make sure that you have the right tool for the job; Vice-Grips aren't real good for this, so you'll need to find that little square-wrench thing. Talk to the auto store people, they'll know what it is.

If the bolt breaks loose, replace it with a non-torx head bolt like I have done to all of mine. Just be sure that the head of the bolt will clear the pump pulley and all.

If the wizzy-out doesn't work out for you, then a heli-coil might be the next best bet. That said, you don't want to leave that area without some kind of fastener!

Good luck

chevelle · #3 (**permalink**) 01-09-07, 02:01 PM

You really need to get the bolt out and use a new one as the pump cover will likely not seal with the fastener missing.

You may have better luck acessing it if you take the right front wheel off and remove the plastic splash panels inside the wheel well. The front of the engine is right there behind the panels and may allow you a better angle to work.

Go to a tool supply house and buy a small diameter carbide drill bit. The carbide bits are very hard and will easily drill the hardened bolt. They are not cheap and they break very easily so use lots of drill RPM and light pressure. Despite the drawbacks of the carbide bits they are the only way to reliably drill the bolt to get an easy out into it.

Take a small diameter drift or punch with a flat end and whack the bolt as hard as you can with a hammer to break it loose in the hole. The bolt was tensioned against the female threads and probably corroded to some extent over time. The various penetrants on the market might help also but a good sharp rap with a hammer and punch trying to drive the broken bolt deeper in the hole will often break it loose so that the easy out can remove it. If you don't do something the easy out will just break also as it is no stronger than the head of the bolt that yielded.

The next time this sort of thing happens use a grinder or dremel with a small disc cutter to cut a slot in the bolt head so that you can use an impact driver and flat bladed screw driver bit to grip it. Working thru the wheel well makes this easier even if you have to loosen the cradle bolts and lower the front of the engine slightly to get to it.

mikes93sedandeville · #4 (**permalink**) 01-14-07, 04:42 PM

Thanks for all the info guys but alas that bolt ain't coming outta that block. I have tried drilling and easy outting it, tried the pb blaster tried major heat and still nothing. In fact I think I have done irrepairable damage to the block trying to drill the bolt as I see a spot on the edge the drill bit messed up. Also the dang thing is at so bad of an angle you can't even swing a hammer. My last hope is that I can just use my torch and melt the gd thing outta there.

illumina · #5 (**permalink**) 01-15-07, 01:39 AM

Even out the hole in the center of the stuck thread and try applying a Heli-Coil in there. If that doesn't work...

NickySantoro · #6 (**permalink**) 01-15-07, 09:53 AM

If this is not the original pump, the replacement may have been installed using red or purple Loctite on the threads. If you can get some heat on it, you may be able to break it loose.

Cad tech · #7 (**permalink**) 01-15-07, 02:07 PM

to access it better remove lower motor mount bolts on passenger side, use a jack a block of wood, and jack that side up should give you alot more access..This is the way i do all these water pumps and inlet pump gasket..