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2000 E430 4Matic, 2007 R320 CDI, 2012 E63 P30, 2013 SLK250
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440 Posts
Discussion Starter #1
i was giving the cooling system an overhaul this weekend and during removal of the three thermostat bolts, one of the bolt heads just broke off! :crybaby2: it was obvious that the housing had not been removed in a while..
now i have the 1 cm remainder of the bolt sticking out of the water pump side of the housing. any ideas on how to remove it? i've already soaked the bolt with PB blaster but didn't want to mess with it until i get some advice...
any help would be appreciated!
 

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2007 S550
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1,165 Posts
You will need to go to a parts store and get what I think is called an "easy out". It's a hardened screw that you first drill a corresponding hole into the remaining stuck stud then tap the easy out into the stud and then screw on out. If it is really stuck sometimes you might need to apply some heat from a torch. Slow and methodical, it will come out. Good luck.:)
 

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1984 300TD
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60 Posts
if you have 1 cm of stud sticking out, dont use an easy out- get a "stud remover/installer" from an autoparts store. with the pb blaster, it should pull it right out.

If it wont budge out, sometimes you can get it to move by tightening it just a bit, then back it out. work it back and forth, spraying it down.

if it is too short for the installer, try a good pair of visegrips.

if that fails, then you may need to grind it off, and try an easy out. but this is a last resort. the surronding metal is prolly way softer thatn the bolt, so it will drill easier. that means you need to be really careful the bit doesnt wnder. also, dont break off the tip of the easyout, it is very hard steel, which also makes it brittle.
 

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'84 300D/ dakota benz trk. Sold... miss it. "88 260E '91 190E 2.6 '89 Volvo 240DL "85 300D
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1,252 Posts
#1 use vise grips work back and forth in no luck go to step 2.
#2 when 1 cm of stud is worn off from trying, grind stud down flat and use center punch to find center and use very small drill bit to start hole and step up drills until ideal hole size for easy out is obtained. if no luck go to step 3.
#3 if hole drilled weird etc. and easy out does not work, drill and tap the hole a size bigger and use new bolt for that hole. if no luck go to step 4
#4 if all else fails, taking a running screaming fit through the neighborhood and when exhausted use a tire iron on the entire car.
 
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