Broken thermostat housing bolt 2001 4.0L SOHC

[texashale]

Hi guys. I'm actually working on a Sport Trac, but looking at various Sport Trac forums, it seems like the guys aren't too savvy. Anyhow. I replaced the thermostat housing on the engine, and when I was trying to get the upper radiator hos on, there wasn't enough room between the thermostat housing radiator hose inlet and the intake manifold to actually get the hose on, so I was trying to see if maybe the thermostat housing wasn't all the way bolted down on the engine, and broke one of the bolts off. I was wondering if anyone had any ideas as to how I can get the bolt out without having to take the intake manifold off? If not, how do I take the intake manifold off? Every youtube video I have seen that describes it has a different intake manifold that has these weird pipe looking parts coming out the sides and wrapping around to the back. Mine looks like a very tall supercharger if that makes sense... I appreciate any help I can get. Mike

 

[RonD]

This is an Explorer 4.0l SOHC lower thermostat page: http://bengrosser.com/howto/fordthermostat/clean-up.php

I normally use a Reverse drill bit in a reversible drill to drill out bolt, smaller size to start.
The act of drilling in the reverse direction usually causes the bolt to just unscrew when drill bit catches a few times.
Move to larger bit after smaller bit is down enough.
Auto parts stores almost always have Reverse drill bits, some hardware stores but less common.

If it doesn't unscrew then you still have hole to try eze-out.


If you can't get at the hole with a drill then yes you will have to start pulling off stuff until you can.

Google: explorer sport trac 4.0l sohc upper intake

Looks to be a few videos with varying types of upper intakes

 

[texashale]

Ron, the problem is the thermostat housing is still in place. I cant get it out because of the bolt. most of the bolt stayed... I will be able to get the bolt out with channel locks probably, but I can't get the thermostat housing out... I should have clarified that. sorry...

 

[RonD]

Then what you may have to do is lift up the thermostat housing as high as you can, take sensors off, and wedge it up, then use hack saw to cut the bolt shaft as high as you can, so you can grip it later.
Once bolt is cut housing should come out.

 

[Haywire6000]

If the bolt threaded in easily by hand and then you over tightened it and broke the head off you can usually get a small pick and spin what's left of the bolt out that way. But if the bolt bound up at all threading in it wont work. The pick trick only works one out of a hundred times. Worth a shot though.

 

[texashale]

Thanks guys. It was tough to get in, I really should have bought new bolts because these were rather rusted. I was thinking about using a sawsall to cut it off, so the hacksaw kinda confirms that idea. Might have to go that approach.