While removing the water pump, due to it's failure, I found the upper driver side water pump bolt to be broken. Unfortunately, it is broken just below the block surface so it is impossible to try the handy Craftsman lock pliers etc.

Well, it may be hard to get to it, but I would recommend drilling it out.
Before drilling, tho, take a flat end(drift) punch, and whack the crap out of the bolt a few times. This helps loosen the threads. Then, use a center punch to make a starting point for the drill bit.
Start drilling small, and go larger, a couple of sizes at a time, until it is drilled out to at least half size. Drill all the way thru the bolt. Then soak it down with penetrant, and take a break.

Try the ease-out then. If it feels like the ease-out is gonna twist off, stop. Keep drilling larger. You may have to drill all the way to threads, and then, with a small center punch, you can knock whats left of the bolt out(sometimes, a piece at a time). Once the bolt is out, be sure to run a tap down thru all of the bolt holes before installing the pump.
It's a big hassle, for sure, but it will work, if there's room, and you have a little patience.


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Joel Adams
C3VR Lifetime Member #56    
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"Money can't buy happiness -- but somehow it's more comforting to cry in a CORVETTE than in a Kia"

Patience is the key to this delima... but you may be able to kill two birds with one stone here... Joel's procedure is spot on, however, if you can find a LEFT HANDED Drill Bit...it might turn the bolt out while drilling the hole, eliminating the need for an easy-out... that is, if'n you can find one... not your everyday on the shelf item at the local Wal-mart, but, possible at a good specialize hardware store or machine shop... just a thought :)

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StingrayJim
NCM Lifetime Member #1936

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both right,sometime reverse drill works.

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1979 Corvette

Thanks for the directions Joel. I have never seen such good detail on how to get broken bolts out. It will definitely give me something to do for awhile so I better get started. Thanks.

The reverse drill deal is nice, and usually works quite well. However... this is a fairly large size bolt(7/16"), AND it goes all the way thru to the water jacket. This means there will be some sort of "funk" on the exposed threads. This makes it a lot harder to remove by just turning it backwards, tho it may work. It really depends on WHY the bolt broke in the first place. Was it cross-threaded? Wrong threads? Too long? Who the heck knows? It's possible it was just a bolt that was already fractured, and snapped, in which case, it may screw right out( it could happen! ).
Another thing is, if the bolt is not too tight in the hole, drilling the normal rotation may screw it on into the water jacket, since it does go all the way thru.
Either method will work the same.
Good luck! Just don't break off any ease-outs in it...that's when the REAL fun starts!

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Joel Adams
C3VR Lifetime Member #56    
My Link


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"Money can't buy happiness -- but somehow it's more comforting to cry in a CORVETTE than in a Kia"

I am just going to take it slow and easy with the plan you've laid out Joel.

got it out???

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1979 Corvette

No, I haven't had time to touch it this week at all. No real plans for the weekend other than work on it so should be able to get it done. I will post results. Thanks for asking.

reverse drill bit may take it out. sometimes the heat from drilling will loosen any gunk that built up or the bolt itself and come out with no problem. as was said take your time.

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LIFETIME MEMBER #97
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Thanks David. A friend loaned me a whole set of reverse drill bits today. So I have regular bits, reverse, punches, easy outs, and as Joel suggested various punches, a big hammer and everything else that should do the job, one way or the other.

one other thing. i (hate to admit it) had a ford bronco. had to change water pump and one of the bolts broke. where it was kind of a pain to get to plus it was a long bolt and didn't want to chance drilling too far. what i wound up doing was to helicoil it. i cut a bolt down to the right length and it held perfectly. 

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LIFETIME MEMBER #97
THE DYNAMIC DUO

The helicoil is a great option if it gets down to it. I have absolutely no reservations about doing that. Our machinist at work had just suggested that to me as well. Thanks for the good idea.

This may not be possible, but depending on if your clear of flammable parts a good hot torch will help break the bolt loose. I've even welded a tit on the stud and turned it with vise grips. Being at the surface of the block or up inside that may not be possible. As the guy's said be real careful not to break an easy out up in there. Been there. REAL UGLY!! You can do it!!! Terry

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Click on images for Before and After pics!

I'm going to get started on it tomorrow AM with an arsenal of stuff to try. I am going to be especially careful with the easy out since I don't want to break that off. Although, I've been telling the better half that if I can't get this bolt out I'll have to get a ZZ4.  I don't think she's buying it though.

I broke an ezout off in my aluminum (factory L-82) intake on the water neck bolt.  They don't come out of aluminum without a BIG mess.

Good Luck!

Relax, have a homebrew and don't get in a hurry!!!

Life is Good!

COOL!!!

Glad to hear it worked!!!

Awesome job!! I knew you could do it!

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Click on images for Before and After pics!

it's always easy to give good advice but you getting it done successfully was the hard part. great to hear it worked out but as you said there goes the zz4 you wanted.

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LIFETIME MEMBER #97
THE DYNAMIC DUO

Glad to hear it came out with no casualties!!!
Good job!

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Joel Adams
C3VR Lifetime Member #56    
My Link


(click for Texas-sized view!)             NCRS

"Money can't buy happiness -- but somehow it's more comforting to cry in a CORVETTE than in a Kia"

NAPA will have the water pump tomorrow so I'll get it slapped in there this week sometime. Then it's off to the next project.

 Working in Fishing in Alaska we get Rusted and Broken Bolts all the Time. There is another Twist to the Left handed Drill they make Bits that are a Comination Bit and Easyout. Looks like they would work Real Good but I have never Tried them. If You have one that is super Stuck Heat it Up as best as You can with a Torch. This will Ruin the Heat Treating and make it easyer to Drill. Then after You get the Hole Drilled Heat it up again till it starts to turn Red. When it Cools it will Shrink. Once Cool it will probably Turn out Very Easy. Richard.......

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My Car...PIC 1     PIC 2

One thing I like to do is ALWAYS clean ALL threads before re-assembly. I first wire brush any bolts I'm reusing and then use a die only if needed. I do run a tap through the bolt holes and the nuts. And just prior to assembly, depending on the application, I always use either a silicone sealer, thread lock or neverseize on the threads. Glad to hear you took your time and did the job the right way. It's a lot better than trying to take short cuts, which hardly ever work out right and end up costing you more, either in money, time and/or aggrivation. When I do the job I KNOW it'll be done right because I won't finish until it is right. And too, I have a sense of accomplishment when completing such projects.