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was replacing thermostat and a problem occured

04-28-2011, 06:12 PM
I was replacing the thermostat on my 2002 dodge ram 1500 and the bottom on the the two bolts was cross threaded i am assuming by the factory because it looks to be the original thermostat but I tried to ease the bolt out of its place and it snapped off on me. Does anybody know a good solution to my problem or what I should do I was thinking of drilling out the bolt and re-tapping the hole for a new screw but I was not sure if that would mess anything up because of any kind of precision machining or something but I went to see if I could get my drill in the small gap and I can;t anyways I also didn't feel very comfortable doing it by hand and thought it should be done by a drill press but if anybody has any good solutions I am all ears thank you

Chris Stewart
04-28-2011, 07:03 PM
Which engine?

04-28-2011, 07:07 PM
the 4.7L V-8

04-28-2011, 08:15 PM
Probably was not cross threaded, it was in an open threaded hole, where the end of the bolt protruded into the water jacket, and the threads became corroded- such that after you broke it loose, the bolt became tighter, and then it snapped while trying to take that corrosion through the threads in the hole. When this happens to me, I seriously think twice about changing the thermostat- and put it back.

Now you are in a pickle...only answer is to drill and tap new hole..

Chris Stewart
04-29-2011, 05:55 PM
Is that the one with the thermostat housing low on the passenger side of the engine?

04-29-2011, 07:26 PM
You can try and drill it and use an easy out.

04-29-2011, 09:21 PM
Never had any luck with easy outs. they normally break on me. Some pblaster or kroll. Left twist drill bit if you can reach it.

04-30-2011, 01:36 PM
I grinded it off as best as i could went to drill it and it would not drill that easy. What I have done and it seems like it has fixed it I have let it run no leaks and it is on there as solid as I can get it... I took a all metal C clamp and i tightened it down as much as I could then tac welded the threads so that the C clamp wouldn't back off of the housing it seems to work very well and It is on there and won't even shake

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