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Removal of broken bolt on thermostat 06 Chevy cobalt

How can I remove the broken bolt stud and what do I need to do

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Brad Brown

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There are a lot of youtube video movies about this process. It can be a mess. Bolts are harder steel than the surrounding metal. Drilling them out and using an easy out is on way. If there is enough stud left to get a grip on it with a vicegrips is another, welding a piece onto it is another and the heat helps loosen it.

Posted on Nov 19, 2016

Testimonial: "The bolt is flush nothing to get a hold of it or weld a nut on it"

  • 1 more comment 
  • Anonymous Nov 19, 2016

    Thank you very much I will drill it and use an easy out I have one I hope it's the one I need

  • Brad Brown Nov 19, 2016

    Start small and use a center punch to get the middle of the stud,

  • Anonymous Nov 19, 2016

    Thanks I appreciate your help



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3 Answers

I have a 2003 Ford Ranger 3.0 and I have an exhaust manifold bolt that has broken off inside the manifold,and the evaporator coil,and other AC parts are in the way .what options do i have on this

With the exhaust manifold off. If there is some of the bolt sticking out. You'll need a torch to heat the head up, red hot around the bolt. Also a pair of needle nose vise grips to grab it with and turn it out. You'll have to heat it several times to get out. No bolt showing, you best bet it to pull the head. Drill the bolt and extract it.

Jul 26, 2016 | Ford Cars & Trucks

1 Answer

What to disassemble to change thermostat

You will need to remove your air cleaner and duct assembly. You will then see the thermostat housing sandwiched between the back of the intake manifold and the exhaust crossover pipe. The service manual says to remove the exhaust crossover pipe, but trust me, you do not want to attempt this unless you have access to a torch to heat the nuts that hold the thing to the exhaust manifolds. If you break a stud, then you are going to be removing an exhaust manifold for broken stud removal. If you take the 8mm screws out of the heat shield on the exhaust crossover pipe, you can wiggle the heat shield out. This will provide enough room to get the lower thermostat housing bolt out. It is a pain to do it this way, but it works and will prevent broken exhaust pipe studs. Sometimes the little 8mm bolts will also break, but since they only hold the heat shield, it is of no great consequence.

Then all you have to do is remove the two bolts that hold the thermostat housing to the manifold. The thermostat is directly under it.
Then the only other real "trick" is getting the thermostat and O-ring to stay in the correct position while you put the thermostat bolts back in. A trick that I use is a small wooden wedge. I put the thermostat housing into place over the thermostat and O-ring, then place mt wedge between the thermostat housing and the crossover pipe to hold the thermostat housing in place while I start the bolts. Otherwise, the thermostat tends to slide out the bottom while you are trying to get the bolts started.

Let me know how it goes...

Jun 16, 2012 | 2002 Buick Rendezvous

1 Answer

Where is the thermostst located in a 2006 cobalt LT 2.2 eng.

Check this diagrams...


Fig. Location of radiator outlet hose clamp (1) at thermostat cover for the removal of the radiator outlet hose from the thermostat cover - 2.2L & 2.4L engines


Fig. Location of thermostat cover bolts for removal of the thermostat and thermostat cover O-ring seal - 2.2L & 2.4L engines

Hope this helps.

Sep 22, 2011 | 2006 Chevrolet Cobalt

1 Answer

How to get the thermostat housing to disconnect. We have taken all bolts loose but will not come apart.

Not sure if you have the 2.7L or the 3.5L so I'll post for both sizes for you:

2.7L Removal procedures
  1. Drain cooling system.
  2. Remove radiator lower hose from thermostat housing.
  3. Remove nuts from heater tube flange studs.
  4. Loosen starter bolt at heater tube bracket.
  5. Pull heater tube out of thermostat housing and position out of the way.
  6. Remove bolt and two studs.
  7. Remove thermostat housing, O-ring and thermostat.
  8. Remove thermostat housing bolts.

3.5L Removal procedures

  1. Drain cooling system.
  2. Raise vehicle on hoist.
  3. Disconnect electrical connectors from engine oil and power steering pressure switches.
  4. Disconnect radiator and heater hoses from thermostat housing.
  5. Remove thermostat housing bolts.
  6. Remove housing, thermostat, and gasket.
The OEM thermostat is staked in place at the factory. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the thermostat housing using a suitable hand held grinder. It is not necessary to restake the replacement thermostat into the thermostat housing

May 07, 2011 | 2003 Dodge Intrepid

1 Answer

How do you replace the thermostat on a 2007 Buick Terraza?

Engine Coolant Thermostat and Housing Replacement, Tools Required: Hose Clamp Pliers.
Removal Procedure IMPORTANT:Use the hose clamp pliers to gently release tension on the hose clamp until the hose clamp lock feature engages allowing removal of the hose.
Fig. 1: View Of Radiator Inlet & Outlet Hoses
  • Drain the cooling system.
  • Using the hose clamp pliers, release the tension on the hose clamp at the thermostat housing and reposition the clamp.
  • Remove the radiator outlet hose from the thermostat housing.
Fig. 2: Identifying Thermostat Housing & Bolt/Stud
  • Remove the thermostat housing bolt/stud.
  • Remove the thermostat housing.
  • Position the thermostat housing.
  • Install the thermostat housing bolt/stud.
  • Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  • Install the radiator outlet hose to the thermostat housing.
  • Using a small flat-bladed screwdriver, release the hose clamp retention lock at the thermostat housing.
  • Fill the cooling system.
FIG 1 1kbron_96.gif

FIG. 2 1kbron_97.gif
Good Luck and Merry Christmas!! A HELPFUL - 4 THUMBS - rating for this solution would be greatly appreciated. Thank you for using FixYa.

Dec 17, 2010 | 2007 Buick Terraza CXL Wagon

1 Answer

How to install thermastat in 1500 chevy pickup 1994

Gasoline Engines
Never open, service or drain the radiator or
cooling system when hot; serious burns can occur from the steam and hot coolant.
Also, when draining engine coolant, keep in mind that cats and dogs are
attracted to ethylene glycol antifreeze and could drink any that is left in an
uncovered container or in puddles on the ground. This will prove fatal in
sufficient quantities. Always drain coolant into a sealable container. Coolant
should be reused unless it is contaminated or is several years old.

  1. Drain the radiator until the coolant is below the thermostat level (below
    the level of the intake manifold).
  2. Remove the water outlet elbow assembly from the engine. Remove the
    thermostat from the engine, or, on the 4.8L, from inside the adapter elbow.
    To install:

  3. Clean the gasket surfaces on the water outlet elbow and the intake manifold.
    Use a new gasket when installing the elbow to the manifold.
  4. Install the new thermostat making sure the spring side is inserted into the
    engine, or, on the 4.8L, downward into the thermostat housing. Tighten the
    thermostat housing bolts to 20 ft. lbs. (28 Nm). On the 4.3L, 5.0L, 5.7L tighten
    the studs to 21 ft. lbs. (28 Nm). On the 7.4L tighten the bolts to 27 ft. lbs.
    (37 Nm).
  5. Refill the cooling system. Start the engine and check for leaks.

    Fig. 1: Remove the thermostat housing bolts

    Fig. 2: Remove the thermostat housing from the engine

    Fig. 3: Remove the thermostat from the housing

    Fig. 4: Thermostat housing - 4.3L engines

    Fig. 5: Thermostat housing - 4.8L engines

    Fig. 6: Thermostat housing - 5.0L and 5.7L engines

    Fig. 7: Thermostat housing - 7.4L engines, R/V series

    Fig. 8: Thermostat housing - 7.4L engines C/K series

Diesel Engines
1988-95 MODELS

  1. Remove the upper fan shroud.
  2. Drain the cooling system to a point below the thermostat.

    Fig. 9: Thermostat housing - 6.2L engines, R/V series

    Fig. 10: Thermostat housing - 6.2L and 6.5L diesel engines -
    1988-95 C/K series

  3. Remove the engine oil dipstick tube brace and the oil fill brace.
  4. Remove the upper radiator hose.
  5. Remove the water outlet.
  6. Remove the thermostat and gasket.
  7. Installation is the reverse of removal.
  8. Use a new gasket coated with sealer, Make sure that the spring end of the
    thermostat is in the engine. Tighten the bolts to 35 ft. lbs. (47 Nm) on 1988-91
    models and 31 ft. lbs. (42 Nm) on 1992-95 models.

1996-98 MODELS

  1. Drain the cooling system to a point below the thermostat.
  2. Disconnect the upper radiator (inlet) hose from the thermostat outlet.
  3. Ufasten the thermostat housing bolt and stud, then remove the housing.
  4. Remove the gasket and the thermostat.
  5. Clean any remaining gasket from the thermostat hosing mating surfaces.

    Fig. 11: Exploded view of the thermostat assembly components
    1996-98 diesel engines

    To install:

  6. Place the thermostat into position in the housing, then install the gasket.
  7. Install the thermostat housing, the bolt and the stud. Tighten the bolt and
    stud to 31 ft. lbs. (42 Nm).
  8. Attach the upper radiator (inlet) hose to the thermostat outlet.
  9. Fill the cooling system.
  10. Start the engine with the radiator cap still removed, until the upper
    radiator hose is hot (this means the thermostat is open).
  11. With the engine idling, add coolant until the coolant level reaches the
    bottom of the filler neck.
  12. Instal the radiator cap making sure the arrows line up with the overflow
    tube and check for coolant leaks.

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Oct 07, 2010 | Chevrolet 1500 Cars & Trucks

1 Answer

Location of engine thermostat

Removal & Installation 3.0L Engine To Remove:
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section
  2. Drain the engine cooling system
  3. Remove or disconnect the following:
    • Air cleaner outlet tube
    • Hoses and remove the thermostat housing assembly
    • Bolts separate the housing and remove the thermostat and seal
To Install:
  1. Install or connect the following:
    • New seal and thermostat. Torque bolts to 8 ft-lbs (11 Nm)
    • Hoses to assembly
    • Air cleaner outlet tube
3.9L Engine To Remove:
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section
  2. Drain the engine cooling system
  3. Remove or disconnect the following:
    • Intake manifold
    • Nuts and remove the hose bracket
    • Stud bolts
    • Lower radiator hose from the thermostat housing
    • Bolts and thermostat housing cover
    • Thermostat and seal
To Install:
  1. Install or connect the following:
    • New seal and thermostat
    • Housing cover. Torque bolts to 8 ft-lbs (11 Nm)
    • Lower radiator hose to the thermostat housing
    • Stud bolts. Torque to 10 ft-lbs (13 Nm)
    • Hose bracket. Torque nuts to 89 in-lbs (10 Nm)
    • Intake manifold

Aug 17, 2010 | 2000 Lincoln LS

1 Answer

Where is the thermastat 2006 la cross

3.6L Engine
  1. Remove the heater hoses.
  2. Remove the throttle body.
  3. Remove the radiator water pipe outlet.
  4. Remove the thermostat and housing.

    NOTE The thermostat and housing are replaced as a complete unit.

  5. To install, reverse the removal procedure. Tighten the housing bolts to 15 ft. lbs. (20 Nm).

3.8L Engine
  1. Remove the fuel injector sight shield.
  2. Partially drain the cooling system.
  3. Remove the radiator inlet hose from the water outlet housing.
  4. Reposition the wiring harness from the water outlet housing stud.
  5. Remove the water outlet housing bolt and the stud.
  6. Remove the water outlet housing and the gasket.
  7. Remove the thermostat.
  8. Clean and Inspect the water outlet housing gasket mating surfaces.
To install:
  1. Install the thermostat.
  2. Install the gasket and the water outlet housing.
  3. Install the water outlet housing bolt and the stud to the water outlet housing and tighten to 20 ft. lbs. (27 Nm).
  4. Install the wiring harness to the water outlet housing stud.
  5. Install the radiator inlet hose to the water outlet housing.
  6. Fill the cooling system.
  7. Install the fuel injector sight shield.

Oct 13, 2009 | 2006 Buick LaCrosse

2 Answers

Cant remove wheel hub

here is procedure

Section 04-01: Suspension and Wheel Hubs, Front 1996 Taurus, Sable Workshop Manual
  1. Raise vehicle on hoist.
  1. Remove wheel and tire assembly. Refer to Section 04-04 .
  1. Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
Brake Shoe and Lining Removal
  1. Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
  1. Raise vehicle on hoist. Refer to Section 00-02 .
  1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
  1. Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
  1. NOTE: It is not necessary to disconnect hydraulic connections.

    Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
  1. Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
  1. Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
  1. Remove inner brake shoe and lining assembly.
  1. Position lug bolt (1107) to clear front wheel knuckle (3K185).
  1. Remove lug bolt from wheel hub (1104).


  1. Install lug bolt into wheel hub.
  1. Using a lug nut (1012), seat wheel hub bolt into wheel hub.
  1. Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
  1. Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).

May 25, 2009 | 1996 Mercury Sable

1 Answer

Stereo removal 06 cobalt

you must remove all the plastic face plates around the radio then remove the radio cautious as you could damage the clips that hold the plates in place.

May 14, 2008 | 2006 Chevrolet Cobalt

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