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        General >> Problems >> Thermostat Housing
        
(Message started by: n880eua on Nov 19th, 2009, 2:18pm)
Title: Thermostat Housing
Post by n880eua on Nov 19th, 2009, 2:18pm
It never rains but pours my end.

I have gone to change the thermostat on my 2.9 12v and guess what.

One of the bolts that holds the thermostat housing has shared off. The rest of the bolt is in the engine still.

Now the bottom one has come out and the top left one also (When your stood at the front of the car) but the top right one is the one thats snapped off.

Whats the best thing to do. My dad says the cars as good as scrap now as there is only 1MM if I am lucky of thread sticking out of the block.

Any help would be good as its got an MOT tommrow and if I could atleast see how that goes I dont mind spending the money on it.
Title: Re: Thermostat Housing
Post by Highlander on Nov 19th, 2009, 3:40pm
Your dad sounds a cheery fellow!  ;D

Plenty of options for removing a sheared stud, it can be drilled out, use a stud extractor or welding a bar onto the end of it is sometimes possible.

Definitely not a huge problem, any garage/engineering shop should be able to sort you out easily enough.
Title: Re: Thermostat Housing
Post by Simmo on Nov 19th, 2009, 3:45pm
In case you are not aware THIS (http://www.screwfix.com/prods/20084/Van-Car-Accessories/Mechanics-Tools/Stud-Extractor-Set-8-Pc?cm_mmc=GoogleBase-_-Datafeed-_-Van%20and%20Car%20Accessories-_-Stud%20Extractor%20Set%208%20Pc) shows the type of thing you need. As Stuart says, drill a hole in the stud, and then insert the extractor. Soak in WD40.
Title: Re: Thermostat Housing
Post by Tons_of_fun on Nov 19th, 2009, 7:41pm
If you are anywhere near birmingham i have a set of extractors you could borrow  :)
Title: Re: Thermostat Housing
Post by gozz on Nov 19th, 2009, 8:09pm
Put it back with two studs for the MOT,use a drop of silicone sealer,let it set before replenishing the coolant.
My Dad tended to be rather like yours,he didn't half make me determined to prove him wrong  ???
               GOZZ.
Title: Re: Thermostat Housing
Post by Highlander on Nov 19th, 2009, 8:26pm
I'm not up on my 12v's Gozz, is the thermostat housing  bolted to the timing cover?

ie  

if the stud couldnt be extracted easily could the whole thing be replaced?
Title: Re: Thermostat Housing
Post by gozz on Nov 19th, 2009, 8:43pm
It's on the front of the inlet manifold which of course bolts down in the 'V' Stuart.
Indeed there would be no problem for him to change that complete.
                                              GOZZ.
Title: Re: Thermostat Housing
Post by Highlander on Nov 19th, 2009, 8:57pm
Well i'm sure i have a spare one of them if you get stuck  n880eua  ;D
Title: Re: Thermostat Housing
Post by Scorpio_Mike on Nov 19th, 2009, 9:13pm
Similar problem on my Sierra XR4i many years ago - one of the bolts that holds the water pump onto the front timing case sheared off ...so I drilled out the remains of the bolt and epoxy ( chemical metal or liquid steel - can't recall the exact brand ) glued a stud ( for stud read bolt with the head cut off  ;D ) into the blind hole, left it for 24hrs and then fittted the water pump - I recently took the engine apart and it is still in there solid.
Title: Re: Thermostat Housing
Post by n880eua on Nov 19th, 2009, 9:30pm
Excellant, many ideas to try then. Don't think I can replace the whole v section.
Title: Re: Thermostat Housing
Post by Highlander on Nov 19th, 2009, 9:33pm
easy ;)
Title: Re: Thermostat Housing
Post by gozz on Nov 19th, 2009, 10:12pm
Definitely  8)
          GOZZ.
Title: Re: Thermostat Housing
Post by n880eua on Nov 20th, 2009, 4:22pm
Car went through the MOT no trouble. Garage had a look at the left over from this bolt and said that if they can't shift it then its a £650 head off and milling job.

Is there anybody local in the South Yorkshire area who could help hear as its leaking quite bad now.
Title: Re: Thermostat Housing
Post by Highlander on Nov 20th, 2009, 4:42pm

on 11/20/09 at 16:22:46, n880eua wrote:
Car went through the MOT no trouble. Garage had a look at the left over from this bolt and said that if they can't shift it then its a £650 head off and milling job.

Is there anybody local in the South Yorkshire area who could help hear as its leaking quite bad now.


Go back and burn them down!! what a rip off!

try somewhere else!
Title: Re: Thermostat Housing
Post by Highlander on Nov 20th, 2009, 4:48pm
Do what Mike did and drill it out then glue in a bit of threaded rod.

I'm pretty sure I have a spare 12v inlet manifold with the housing attached, its fairly simple to replace even with limited experience.

Sections 11 to 16 here  shows how to replace the manifold, its really only a few bolts and some gaskets

http://www.fordscorpio.co.uk/manual/engines/12v/V612VDismantle.pdf
Title: Re: Thermostat Housing
Post by Simmo on Nov 20th, 2009, 5:13pm
For a few quid at Screwfix or similar and a bit of work with a drill it makes that garage quote look extortionate which of course it is.  ::)
Title: Re: Thermostat Housing
Post by joe-satch on Nov 20th, 2009, 5:20pm
why would the head have to come off???..the stat housing is set in the inlet manifold....in the past i have deal with broken studs this way(mostly water pump bolts)....heat up the broken stud..i use a blow-lamp....using mole grips...on the 1mm thats sticking out..it should un-screw..works everytime for me...mind you i have never had a stat housing bolt snap on my 12v..but a friend of mine did...but i got it out using the method that i discribed  :).
Title: Re: Thermostat Housing
Post by twinturbo on Nov 20th, 2009, 5:44pm
Dremmel a slot for a screwdriver. nice and deep.

If you can use a ratchet fitted with a screwdriver attatchment so you can apply decent force without twisting.

If that does not work,

Drill , retap, replace with un-equal stud.


TT
Title: Re: Thermostat Housing
Post by n880eua on Nov 20th, 2009, 6:28pm
Well I have left it with them to try again.

I will be picking it up in the morning with the bolt left in or not eitherway. I think it needs to come off to be drilled due to lack of space at the front.

Eitherway I will have to get it sorted. Anybody know if Ford still stock the thermostat bolts and does anybody know where the sensor is that feeds the dash the coolant tempreture.
Title: Re: Thermostat Housing
Post by gozz on Nov 20th, 2009, 8:14pm
In the left side of the intake manifold under the plenum and behind the thermostat.It's the smaller one of the two,13mm spanner,single push on wire.Best whip off the air intake pipes and the plenum to make the job easy.The thermostat bolts are only plain 10mm headed,any will do.
                                          GOZZ.
Title: Re: Thermostat Housing
Post by n880eua on Nov 21st, 2009, 6:44pm
Still stuck with this. Garage tried to shift it with no luck. So they say. They wanted to strip it all down.

So has anybody got a 12V inlet manifold as I fear it might be my only option to get it going again as it deffo leaks and there is no access to get a drill in there to drill it out. Also still got to got to cut the bit of the bolt that remains first.

Why oh why did Ford have to use such cheap and nasty fasteners. Never had these problems from my Rover 820.
Title: Re: Thermostat Housing
Post by PJDavis on Nov 21st, 2009, 11:08pm
Probably a bit late now!   A product:  Rost-Off-Ice by 'Wurth'  Use this to get out rusty bolts or nuts.   Smells like Germaline.   Very good.   I have used on many occassions, one of my successes include rusted-in brake-bleed-nipples.   When a bolt is sheared level, use this Rost Off Ice and after only a couple of minutes take a nice sharp centre-punch and hit with a small Ball-Pein-Hammer anti-clockwise.   Don't hit it hard!   Just small sharp taps well-aimed.   Patients will get success,   I've recently knocked out a couple of stubborn rocker-cover bolts that had been snapped level on my Ultima.   Give the bolts a tiny spray every couple of minutes if it takes a while.   I work a lot on Motorcycles, that have issues with different metals acting as 'Annode/Cathode' and it always works!
Hope this helps, Peter.
Title: Re: Thermostat Housing
Post by gozz on Nov 21st, 2009, 11:13pm
n880eua.
Surely Highlander offered to help  ??? where are you in South Yorks ?
                                         GOZZ.
Title: Re: Thermostat Housing
Post by n880eua on Nov 22nd, 2009, 8:45am
Im in Rotherham, just outside Sheffield
Title: Re: Thermostat Housing
Post by joe-satch on Nov 22nd, 2009, 10:30am
n880eua,people have tried to offer you solutions to your problem,what is stopping you taking there advice??. :)..ok the bolt has snapped..but the thread dont go into the inlet manifold that deep..drill it out and re-tap the next size thread up....or heat it up with a blow lamp and use mole grips to unscrew it.the fact that a garage said they cant do it..dont mean it cant be done. :).


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