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bolts breaking is a result of incorrect steel being used in the bolt manufacture and is not a fault of the vehicle manufacturer.
Discuss this problem with a engineering shop that specialises in rebuilding performance engines as they use a better quality bolt than what is used in mass assembly
every time you rebuild an engine , it is good practice to replace all bolts that are subject to a tension setting and if the manufacturer is aware of a bolt failure then it is more than likely that all stocks of the faulty batch of bolts would have been replaced
As a side point to this saga ---- quite some time ago now, a high rise steel worker was killed while tightening up a construction quality bolt(1") in dia after the bolt broke during tensioning and he fell and died. A subsequent investigation found that the bolt was of inferior quality and a nation wide investigation of bolt stocks found that that just about every bolt used by the US military had to be replaced
The bolts were all substandard and billions of dollars were lost by the bolt manufacturing companies to ensure that the bolts met a standard now used in industry
The first thing you need to do is to think about why the bolt broke in the first place. Was it being turned in the wrong direction? Or was it just really corroded? I've seen mechanics who've been in the buisness many years turn a bolt the wrong way. Anyone can do it. Is any of the bolt sticking out? If so get some "KROIL" it is a release agent of the highest quality. If you can't locate Kroil brand then use something like liquid wrench and spray the bolt right where it goes in. Let it sit then spray it again. I would probably heat the block right next to the bolt with a heat gun if I could do that safely (ie nothing will catch fire). The heat is to expand the junction between bolt and engine block. Then spray the KROIL on the bolt again. Grab the end of the bolt with vicegrip locking pliers to get it out. Make sure to get them on there as tight as you possibly can, and make sure you're turning it the right way to get it out. If the bolt is broken off below the surface you should still spray it with KROIL, but you'll need to drill a hole down the exact center of the broken off bolt down far enough to allow an "easy out." An easy out is a special tool that that has super coarse opposite direction threads that turns in tighter into the bolt as you use it. As you try to turn the easy out further into the bolt, you're actually unscrewing the bolt from the engine block. You'll want to make sure and measure the length needed for the replacement bolt, and take a piece with you to the store to be sure to get the right thread - metric or standard - coarse or fine. And be sure to figure out why the bolt broke in the first place. Good luck
To replace the bolt you'll need to remove the broken bolt that is still in the head. To do this you need to drill a hole in the center of the bolt. And then you'll need to use a bolt extractor to screw the broken bolt out. than you can install a new bolt.
Asuming you broke it off in a blind hole, if you have a wire feed center a nut over the remaning stud & weld if on let cool put penetrating oil on it & work it gently back & forth even if its below the surface slightly on aluminum or cast the weld will not bond to the surface just the bolt you may need to do this process several times then go to dealler for new bolt. Note this works extremly well on broken ex. manifold bolts, we havent drilled in years hope this helps Danny
YOU NEED TO BUY CORRECT SIZE NEW OIL DRAIN PLUG. YOU TO KNOW YOUR THREAD SIZE ON NEW OIL DRAIN BECAUSE YOU NEED THE RIGHT TAP AND DRILL BIT TO CENTER DRILL THE BROKE BOLT IN SIDE OIL PAN YOU NEED A CENTER PUNCH TO PUNCH A SMALL ENOUGH TO START THE DRILL BIT DEAD CENTER OF BROKE BOLT.OIL PAN NEED TO BE REMOVED TO DRILL HOLE STRAIGHT.THIS IN NOT A EASY JOB.EITHER YOU REPAIR OR DAMAGED OIL PAN DRAIN PLUG HOLE. YOU DRILL BIT HAS TO STRAIGHT WHILE DRILLING HOLE DEAD CENTER OF BROKEN BOLT YOU NEED TO MEASURE LENGHT OF OIL DRAIN PLUG BOLT. THEN USE A PIECE TAPE ON DRILL BIT WRAP A PIECE TAPE AROUND DRILL BIT THE DEPT YOU NEED TO DRILL THROUGH BOLT. LIKE I SAY THIS JOB TAKE SKILL AND A STRAIGHT HAND. BECAREFUL WITH DRILL AND WEAR SAFETY GOGGLES. DONT DO THIS FIX IF YOU NOT SURE OF MECHANIC SKILLS YOU WILL EITHER DAMAGE THE OIL PAN OR FIX THE PROBLEM.
Remove the lower four bolts (hope you did not lose any broken pieces into the trans.) and holding the part in a vice, remove the broken bolt and the nose piece that broke off. You may have to use a little extra force to get the new special bolt all the way in due to some damaged threads; put some sealer on the gasket and refit
Ouch! Was it from over-tightening or trying to remove the bolt?
Really, I need more information...
Regardless, you'll have to take the thermostat housing off and remove that broken portion of the bolt. The reason I asked if it was from overtightening, it should be a little easier since the threads aren't locked-up, to remove the bolt section. Hopefully there's enough bolt shank sticking up to lock some vice-grips to.
If the bolt broke trying to loosen it, you may have to drill into the broken bolt remnant and use an "Easy-out" to extract it.
I know... big pain. You can do it. Hey, stuff happens. Good luck!