Oh Dear!

[grey_ghost]

Hi All,

I am pulling off the ancillaries off my engine so that I can tidy them up and tidy/paint the engine block, replace gaskets/seals, etc.

I am not even sure what to call it - but I am trying to remove the casing above the water pump. I soaked the nuts in WD-40 for a week, multiple times. And I was extremely gentle when removing the nuts..

First nut came out - no problems at all. Easy.
http://i1155.photobucket.com/albums/p549/tomb1971/IMG_2478_zpse001d335.jpg

The heads snapped off the next 2... :censored:
http://i1155.photobucket.com/albums/p549/tomb1971/IMG_2476_zps0cffd78a.jpg

What are my options? I know that I can buy a special drill bit and try to drill out the nut, but I am very worried because the thread is quite long. My worry is that I will end up damaging the actual case and then having to try and re-bore the case thread.

Is it wrong to just leave them in there? I know that this is not the perfect solution, but I don't think that my skills are good enough to drill the threads out... :(

What do you think?

[incisor]

an early 2.25 motor...

the housing should just lift off now and you should get access to where the bolts go into the head casting on the thermo stat seat.

soak the threads in your favourite penetrating oil

and after a few days heat whats left of the bolts with what ever you have or can get hold of then let them cool and then soak in oil again for a few days

use vice grips on the bolts to try and free them. tapping them on the top of the bolt with light - medium weight should help loosen them as well.

look after the top of the thermostat housing as they are rocking horse manure.

[mick88]

Incisor is right, just keep tapping them and once they loosen a bit just rock them back and forth and keep soaking down into the threaded area with whatever you are using.
Patience is the big thing here!
Take your time and keep letting them sit and soak.
Good Luck!

Cheers, Mick.

[tailslide]

Once you remove the housing you can then weld a nut onto the end of the bolts and have another go. The heat from welding will also help to loosen the threads. Continue to use penetrating old with hot and cold cycles on the bolts and they should come out without drilling.

Cheers
Ron

[grey_ghost]

Hi All,

No luck so far... The casing is stuck-on tighter than a fishes ...

I haven't even got the casing off yet - let alone the bolts... :(

I know that patience is a virtue - I have soaked the top of the thread with a penetrating oil, and tried tapping the casing gently.. I did this 3 times on Saturday and 3 times on Sunday.

I am just hoping that by repeating the process each day, over the coming weeks it will eventually free up..

[incisor]

you'll get there!

just keep tapping the housing and oiling down the holes as best you can

if you have a small dolly use it on the housing with a small hammer on the other side and try induce a little stretch, anything to break the bind. even a bit of heat on the housing where the bolts run thru.

it took a ages for mine to free up when i first pulled it off

use heaps of never seize when you put it back :p

[Ancient Mariner]

Look up Loctite freeze and release:)

AM

[grey_ghost]

Well the good news the thermostat housing is off!

For the past week I have used Penetrite - and rubber mallet, and patience...

I tried using "Freeze and release" and perhaps it helped, although I doubt it because I think that the bolts have rusted and swollen in the casing..

The bad news - when the thermostat housing came free today the bolts completely broke off. :mad:

So now I have bolts stuck in the thread of the block AND the actual thermostat housing..

Murphy's law I suppose...

I managed to remove one bolt from the actual housing - being incredibly gentle with a hole punch, drilling a small hole, and using a screw out..

I will work on the 2nd bolt tomorrow...

I'm too scared to even try what's left of the bolt in the actual block.. :(

[wrinklearthur]

--- I'm too scared to even try what's left of the bolt in the actual block..

That bolt is in cast iron and shouldn't have the corrosion bind of the steel in aluminium has, so the freeze and try method should work well to remove that one, but gently does it.
.

[grey_ghost]

Hi All,

With the help of a mate, and a lot of patience - I've finally fixed the problem...

It all started about a week ago - when I tried to remove the thermostat housing and 2 of the bolt heads sheared off...

I tried soaking the bolts in WD40, so that I could at least remove the thermostat housing - twice daily for a few days. No luck.
I then moved onto Penetrite - same deal. No luck - things would not move.
I tried "freeze and release" - same deal. No luck - things would not move.
I used a rubber mallet and a block of wood, gently taping in all directions - horizontal and vertical.

http://i1155.photobucket.com/albums/p549/tomb1971/Roger%20-%201960%20Land%20Rover/IMG_2476_zps0cffd78a.jpg

Finally the housing came free - problem was that the bolts had then sheared off...

First problem - the bottom of the bolts are stuck in the engine block...
Next problem - the actual bolts were also stuck in the thermostat housing.

I got the threads out of the block reasonably easily - center punch a hole, drill it very carefully and then use a "screw out"...

Getting the 2 remaining bolts out of the thermostat housing took a further 3 hours, 4 drill bits, wd40, lots of patience, a hammer/punch and lastly some heat.. The bolts had literally expanded and rusted in solid. My mate that was helping me could not believe how difficult it was to remove them without damaging the thermostat housing.. I can't repeat the words...

Here is what is left of the bolts:
http://i1155.photobucket.com/albums/p549/tomb1971/Roger%20-%201960%20Land%20Rover/IMG_2521_zps10fdb3b9.jpg
And the thermostat housing -
http://i1155.photobucket.com/albums/p549/tomb1971/Roger%20-%201960%20Land%20Rover/IMG_2524_zps88a64a2b.jpg
And the block -
http://i1155.photobucket.com/albums/p549/tomb1971/Roger%20-%201960%20Land%20Rover/IMG_2525_zps57955288.jpg

I never, ever want to go through that again...

:wasntme:

[incisor]

glad to see you prevailed in the end!

keep up the good work.....

[123rover50]

Hi All,

No luck so far... The casing is stuck-on tighter than a fishes ...

I haven't even got the casing off yet - let alone the bolts... :(

I know that patience is a virtue - I have soaked the top of the thread with a penetrating oil, and tried tapping the casing gently.. I did this 3 times on Saturday and 3 times on Sunday.

I am just hoping that by repeating the process each day, over the coming weeks it will eventually free up..

Well done on removing it.
I have heard brake fluid is usefull in those circumstances, but have not tried it yet.