Re: Broke off thermostat housing bolt-Help! - Saab 9-5 Bulletin Board - Saabnet.com
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If only the bolt head is broken off, you might be able to remove the thermostat housing and grab the stump with a Wisegrip and get it out.
If it is flush with head, you have to drill and use an extractor unless the bolt is moving freely enough that you might use a sharp chisel and give it some light whacks in the right direction and get the bolt going outwards.
Keep in mind that the rubber gaskets are not good and they stiffen up quickly and especially if you are using cheap after market thermostats.
The aluminum housing will also warp over time so what I do is to mount a flat file in the wise and reshape (flatten) the housing back by sliding it over the file with even pressure.
Anders
SWEDECAR
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