1986 900s 2 months ago - thermo head too. the aft bolt head sheared.
tried to stud weld a new thread to it but it didn't last in any torquing.

Removed the end bango bolt on the fuel rail and stuck a rubber plug in the rail, cleaned up the piddled gas, then I was able to drill straight into the old bolt shaft- adding a drop of oil to the bit every few moments.I then tried the easy out but felt it too would break in place. I was afraid to put a torch on a spot so close to the fuel rail! and a heat gun wasn't gonna be enough and I've never torched aluminum- and there's that law of unintended consequences.

Although I used a nailset to dimple the shaft head, the initial thin bit (1/8th) hole walked a hair offcenter on the uneven shaft head( probably cause by softer flux from the stud weld attempt) but was reasonably on center. I gradually sized up the bit until I was able to use a tap- which worked with relative ease and modest starting pressure. To finish I used a fair amount of anti-sieze to the new bolt shafts and then RTV around on the head housing edge.(Yes I know there's that ring gasket on the thermo edge but I'm a "belt and suspenders" guy at this point) I also replaced the adjacent "elbow" cooling hose on the engine "front" which was pretty dried out.

A tedious job but glad it finally worked out.

posted by 67.80.58...

• Whatdayudoo when you snap off a bolt?, Jim Stevens, Mon, 9 Feb 2009 20:18:58
  • Sometimes, drill hole, cut or file slot out into head., RayF, Tue, 10 Feb 2009 12:42:24
  • Re:Snap off a bolt? Anti-seize, Saabnutt, Tue, 10 Feb 2009 06:42:58
  • (*^% Thermostat housing bolt, Steinway, Tue, 10 Feb 2009 06:32:03
  • me too 2 mos ago, jtm, Tue, 10 Feb 2009 05:38:07 <-- Viewing This Message
  • congrats. it doesn't always work so well..., Paul Bob, Mon, 9 Feb 2009 20:27:14
    • and what about ..., myspv, Mon, 9 Feb 2009 21:15:55
      • Re: "A "arm. broken bolt !..Welding?, Saabnutt, Tue, 10 Feb 2009 06:53:53
        • Re: "A "arm. broken bolt !..Welding?, myspv, Tue, 10 Feb 2009 08:08:07
          • Re: "A "arm. broken bolt !..Flush to frame, Saabnutt, Tue, 10 Feb 2009 08:47:12
            • I think lower A arm bolts have a flat head, like a..., RayF, Tue, 10 Feb 2009 12:57:06
            • lower "A" arm, myspv, Tue, 10 Feb 2009 11:47:15
              • Re: lower "A" arm, oldsaab, Tue, 10 Feb 2009 16:11:34
                • I can't wait to try that, myspv, Tue, 10 Feb 2009 20:47:43

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